Washable diaper and methods of assembly and manufacture

ABSTRACT

A washable diaper having an outer article and an inner liner system detachably coupled to the outer article is disclosed. The inner liner system may include front and back ends and a liner member about a washable article with an absorbent pad positioned therein. The outer article may include front and back ends with opposing side edges extending therebetween. The outer article may include an inner surface with substantially liquid impervious compartments at the front and back ends. The outer article and the inner article may include fastening mechanisms configured to removably couple the inner liner system to the outer article such that at least the front and back ends of the washable article of the inner liner system are substantially secured within the front and back liquid impervious pockets, respectively, when the outer article and inner liner system are assembled.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/469,357, filed May 20, 2009, the disclosure of which ishereby expressively incorporated herein by reference in its entirety.

FIELD OF INVENTION

The invention relates generally to diapers. More particularly, thepresent invention relates to washable and reusable diapers.

BACKGROUND INFORMATION

Disposable diapers and cloth diapers for the absorption and containmentof urine and other bodily excrements are generally known in the art.Disposable diapers have been convenient, but are costly and presentenvironmentally adverse consequences.

Cloth diapers with flushable components have been developed, butcontinue to be inconvenient, bulky, and present unsanitary conditionsbecause of inadequate construction of the diaper. Cloth diapers areoften used in conjunction with waterproof plastic pants to provide someprotection against leakage. Unfortunately, adding this additionalelement does not generally solve the longstanding waste constraint anddisposal difficulties.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a solution to these identified problems.The present invention provides a durable washable diaper with theconvenience and effectiveness of a traditional disposable diaper withoutthe adverse environmental consequences. Consumers will save money andreduce consumer waste because the washable diaper and the absorbentarticles are reusable. The liquid pervious liner of the inner linersystem, captures any non-liquid waste, and is easily removable in itsentirety and disposed through a regular toilet. The option of theimmediate disposal of solid bodily waste provides increased sanitaryconditions.

The present invention provides in one aspect a washable diaper thatincludes an outer article, and an inner liner system. In some suchembodiments, the outer article is configured with a first end includinga first substantially liquid impervious compartment, a second endincluding a second substantially liquid impervious compartment and amedial portion with opposing side edges extending between the first andsecond ends thereof. In some such embodiments the outer article furthercomprises an inner surface and an outer surface. In some suchembodiments, the inner liner system comprises at least one washablearticle having a first end and a second end. In some such embodiments,when the inner liner system is assembled with the outer article, theinner liner system is detachably coupled to the outer article andadjacent the inner surface thereof, the first end of at least the atleast one washable article of the inner liner system is positionedwithin the first compartment of the outer article, and at least thesecond end of the at least one washable article of the inner linersystem is positioned within the second compartment of the outer article.

In some embodiments the outer article defines a perimeter including theopposing side edges, and wherein at least a portion of the perimeterincludes at least one substantially liquid impervious member securedthereto. In some such embodiments the substantially liquid imperviousmember is sewn over the perimeter of the outer article by substantiallynon-wicking thread. In some such embodiments, the substantiallynon-wicking thread is a polyester thread.

In some embodiments the outer article defines a medial portion extendingbetween the first and second substantially liquid imperviouscompartments. In some such embodiments, the first and secondcompartments are positioned on an inner surface of the outer article andinclude an opening accessible from the medial portion of the outerarticle. In some such embodiments, the outer article includes asubstantially liquid impervious material, and the first and secondcompartments of the outer article are formed at least in part from theouter article being folded over upon itself such that the inner surfaceof the outer article forms opposing interior surfaces of the first andsecond substantially liquid impervious compartments. In some suchembodiments, the outer article defines a perimeter, and at least aportion of the perimeter of the outer article includes at least onesubstantially liquid impervious member secured thereover viasubstantially non-wicking thread. In some such embodiments, the at leastone substantially liquid impervious member and substantially non-wickingthread forms substantially liquid impervious opposing sides edges of thefirst and second substantially liquid impervious compartments.

In some embodiments, the washable diaper further comprises at least onefastening mechanism for detachably coupling the inner liner system tothe outer article such that the first end of the inner liner system isselectively secured within the first substantially liquid imperviouscompartment of the outer article and the second end of the inner linersystem is selectively secured within the second substantially liquidimpervious compartment of the outer article. In some embodiments, the atleast one fastening mechanism includes a first fastening mechanismcomprising a first component associated with the outer article and asecond component for mating with the first component associated with theat least one washable article for detachably coupling the inner linersystem to the outer article such that the first end of at least the atleast one washable article is selectively secured within the firstsubstantially liquid impervious compartment of the outer article. Insome such embodiments, the at least one fastening mechanism furtherincludes a second fastening mechanism comprising a third componentassociated with the outer article and a fourth component for mating withthe third component associated with the at least one washable articlefor detachably coupling the inner liner system to the outer article suchthat the second end of at least the at least one washable article isselectively secured within the second substantially liquid imperviouscompartment of the outer article. In some such embodiments, the innerliner system further comprises a liner member fabricated from asubstantially liquid pervious biodegradable material, and the at leastone fastening mechanism detachably couples the liner member to the outerarticle and the at least one washable article such that at least aportion of the liner member substantially covers at least a portion ofan inner surface of the at least one washable article when the innerliner system is assembled with the outer article.

In some embodiments, the at least one washable article includes aninternal cavity with an opening, and the inner liner system furthercomprises at least one absorbent pad removably secured within theinternal cavity. In some such embodiments, the opening of the at leastone washable article and the at least one absorbent pad are configuredsuch that the opening defines a length that is greater than the largestlength of the at least one absorbent pad. In some such embodiments, theat least one washable article includes fastening mechanisms configuredto bias the opening in an open position when the fastening mechanism arefastened. In some such embodiments, the longitudinal length of theopening is at least about 80% of the longitudinal length of the at leastone absorbent pad.

In some embodiments, a portion of the medial portion of the outerarticle comprises side barrier assemblies at the opposing side edges. Insome such embodiments, each side barrier assembly comprises asubstantially liquid impervious barrier panel with a generallysemicircle shape including a substantially curved edge and asubstantially linear edge.

In some such embodiments, each side barrier assembly further comprisessubstantially liquid impervious banding secured over the substantiallycurved edge of the corresponding barrier panel and the correspondingside edge of the outer article with substantially non-wicking threadsuch that the barrier panel and the outer article are coupled to oneanother, form a substantially liquid impervious seal therebetween, andthe corresponding barrier panel is biased in a direction extendingsubstantially away from the inner surface of the outer article. In somesuch embodiments, each side barrier assembly further comprises anelasticized member coupled to the substantially linear edge of thecorresponding barrier panel such that the elasticized member biases atleast the inner surface of the medial portion of the outer article intoa generally convex shape.

In some embodiments, the outer article includes a generallypocket-shaped member removably attached to the outer surface thereofproximate to the second end.

In some embodiments, the outer article further comprises side barriers,the side barriers extending from the inner surface and orientedsubstantially parallel to each other, and the inner liner system ispositioned fully between the side barriers to inhibit movement thereofwhen the inner liner system is assembled with the outer article.

In accordance with another aspect, a method of assembling a washablediaper is disclosed. In some embodiments, the method of assembling awashable diaper comprises obtaining a reusable outer article, obtainingat least one washable article, and detachably coupling the at least onewashable article to the reusable outer article. In some suchembodiments, the reusable outer article has a front end, a back end, amedial portion with opposing side edges extending between the front andback ends thereof, an outer surface and an inner surface. In some suchembodiments, the inner surface includes a first substantially liquidimpervious compartment positioned at the front end of the reusable outerarticle and a second substantially liquid impervious compartmentpositioned at the back end of the reusable outer article. In some suchembodiments, the at least one washable article has a first and secondend and inner and outer surfaces. In some such embodiments, the methodincludes positioning the first end of the at least one washable articlewithin the first substantially liquid impervious compartment of thereusable outer article and the second end of the at least one washablearticle within the second substantially liquid impervious compartment ofthe reusable outer article.

In some embodiments, the first and second substantially liquidimpervious compartments include an opening accessible from the medialportion of the reusable outer article. In some such embodiments, theouter article comprises a substantially liquid impervious material. Insome such embodiments, each of the first and second compartments of theouter article are formed at least in part from the substantially liquidimpervious material of the outer article.

In some embodiments, each of the first and second compartments of theouter article are formed at least in part by the substantially liquidimpervious material of the outer article being folder over upon itself.In some such embodiments, outer edges of the outer article include atleast one substantially liquid impervious member secured thereover viasubstantially non-wicking thread, and the at least one substantiallyliquid impervious member and thread forms opposing substantially liquidimpervious sides of the first and second compartments.

In some embodiments, the outer article and the at least one washablearticle include mating fastening mechanisms for detachably coupling theat least one washable article to the reusable outer article such that atleast the first end of the at least one washable article is selectivelysecured within the first substantially liquid impervious compartment ofthe reusable outer article and at least the second end of the at leastone washable article is selectively secured within the secondsubstantially liquid impervious compartment of the reusable outerarticle when the fastening mechanisms are coupled to one another. Insome such embodiments, the step of detachably coupling the at least onewashable article to the reusable outer article includes fastening themating fastening mechanisms to one another.

In some embodiments, the method further comprising the steps ofobtaining a liner member fabricated from a substantially liquid perviousbiodegradable material, substantially covering at least a portion of theinner surface of the at least one washable article with the linermember, and detachably coupling the liner member to the at least onewashable article and the reusable outer article. In some suchembodiments, the steps of detachably coupling the liner member to the atleast one washable article and the reusable outer article, anddetachably coupling the at least one washable article to the reusableouter article are accomplished at least in part by coupling matingfastening mechanisms associated with the at least one washable articleand the reusable outer article to one another.

In some embodiments, the method further includes the steps of obtainingat least one absorbent pad, removably positioning the at least oneabsorbent pad within a cavity in the at least one washable articlethrough an opening in the at least one washable article, and unfasteningfastening members provided on the one washable article and therebybiasing the opening of the washable article in an open position to biasthe opening in a closed position.

In accordance with another aspect, a method of manufacturing a washablediaper is disclosed. In some such embodiments, the method includes thestep of manufacturing an outer article of the washable diaper. In somesuch embodiments, the method of manufacturing an outer article of thewashable diaper includes the step of forming a first substantiallyliquid impervious portion of a shape that includes a front end, a backend, a medial portion with opposing side edges extending between thefront and back ends, an outer surface and an inner surface. In some suchembodiments, the method of manufacturing an outer article of thewashable diaper further includes the step of folding a first compartmentportion of the first substantially liquid impervious portion that isadjacent the front end towards the back end thereof such that the innersurfaces of the first compartment portion and the adjacent portion ofthe first substantially liquid impervious portion form a firstcompartment with a substantially liquid impervious bottom edge and anopening accessible from the medial portion of the first substantiallyliquid impervious portion. In some such embodiments, the method ofmanufacturing an outer article of the washable diaper further includesthe step of coupling at least one second substantially liquid imperviousportion over at least the side edges of the first compartment such thatthe side edges of the first compartment are substantially liquidimpervious. In some such embodiments, the method of manufacturing anouter article of the washable diaper further includes the step offolding a second compartment portion of the first substantially liquidimpervious portion that is adjacent the back end towards the front endsuch that the inner surfaces of the second compartment portion and theadjacent portion of the first substantially liquid impervious portionform a second compartment with an opening accessible from the medialportion of the first substantially liquid impervious portion. In somesuch embodiments, the method of manufacturing an outer article of thewashable diaper further includes the step of coupling at least one thirdsubstantially liquid impervious portion over at least the side edges ofthe second compartment such that the side edges of the secondcompartment are substantially liquid impervious.

In some embodiments, forming the first substantially liquid imperviousportion includes cutting the first substantially liquid imperviousportion out from substantially liquid impervious material. In some suchembodiments, cutting the first substantially liquid impervious portionout from substantially liquid impervious material includes utilizing atemplate in the shape of the first substantially liquid imperviousportion.

In some embodiments, the at least one second and third substantiallyliquid impervious portions are portions of substantially liquidimpervious banding, and wherein coupling the second and thirdsubstantially liquid impervious portions over the opposing side edges ofthe first and second compartments, respectively, includes stitching thesubstantially liquid impervious banding thereto with substantiallynon-wicking thread. In some such embodiments, the sewing of thesubstantially liquid impervious banding over the side edges of the firstand second compartments, respectively, with substantially non-wickingthread includes sewing the substantially liquid impervious banding overthe side edges of the first and second compartments, respectively. Insome such embodiments, the sewing the substantially liquid imperviousbanding over the side edges of the first and second compartments,respectively, includes sewing with polyester thread via a ball needle.In some other such embodiments, the sewing of the substantially liquidimpervious banding portions over the side edges of the first compartmentincludes passing the substantially non-wicking thread at least throughthe substantially liquid impervious banding portions a first time, thefirst compartment portion of the first substantially liquid imperviousportion, the portion of the first substantially liquid imperviousportion adjacent the first compartment portion forming the firstcompartment, and the substantially liquid impervious portions a secondtime, and wherein the sewing of the substantially liquid imperviousbanding portions over the side edges of the second compartment includespassing the substantially non-wicking thread at least through thesubstantially liquid impervious banding portions a first time, thesecond compartment portion of the first substantially liquid imperviousportion, the portion of the first substantially liquid imperviousportion adjacent the second compartment portion forming the secondcompartment, and the substantially liquid impervious substantiallyimpervious material a second time.

In some embodiments, manufacturing an outer article of the washablediaper further comprises manufacturing side barrier assemblies on themedial portion of the first substantially liquid impervious portion ateach opposing side edge thereof.

In some such embodiments, manufacturing the side barrier assembliescomprises forming second and third substantially liquid imperviousportions of a generally semicircle shape including a substantiallycurved edge and a substantially linear edge. In some such embodiments,manufacturing the side barrier assemblies further comprises securingsubstantially liquid impervious banding over the substantially curvededge of the second substantially liquid impervious portion and one ofthe opposing side edges of the first substantially liquid imperviousportion with substantially non-wicking thread such that the first andsecond portions are coupled to one another, form a substantially liquidimpervious seal therebetween, and the second portion is biased in adirection extending substantially away from the inner surface of thefirst portion. In some such embodiments, manufacturing the side barrierassemblies further comprises securing substantially liquid imperviousbanding over the substantially curved edge of the third substantiallyliquid impervious portion and the other of the opposing side edges ofthe first substantially liquid impervious portion with substantiallynon-wicking thread such that the first and third portions are coupled toone another, form a substantially liquid impervious seal therebetween,and the third portion is biased in a direction extending substantiallyaway from the inner surface of the first portion. In some suchembodiments, manufacturing the side barrier assemblies further comprisessecuring an elasticized member to the substantially linear edge of eachof the second and third substantially liquid impervious portions suchthat the elasticized members bias at least the inner surface of thefirst substantially liquid impervious portion into a generally convexshape.

In accordance with another aspect, an inner liner system for use with anouter article of a washable diaper is disclosed. In some suchembodiments, the inner liner system comprises an elongate washablearticle defining a first longitudinal length greater than a firstlateral width and including an internal cavity and a longitudinallyextending opening in a medial portion of the first width incommunication with the internal cavity that defines a secondlongitudinal length. In some such embodiments, the washable article issubstantially liquid pervious and absorbent. In some such embodiments,the inner liner system further comprises an absorbent pad that issubstantially liquid pervious and absorbent that defines a thirdlongitudinal length. In some such embodiments, the absorbent pad and theinternal cavity of the washable article are configured such that theabsorbent pad can be carried within the cavity when the inner linersystem is used with the outer article.

In some embodiments, the second longitudinal length of the opening ofthe washable article is at least about 80% of the third longitudinallength of the absorbent pad. In some embodiments, the at least onewashable article includes fastening mechanisms configured to bias theopening in an open position when the fastening mechanism are fastened.

Other objects, aspects and advantages of the present invention, and/orof the currently preferred embodiments thereof, will become more readilyapparent in view of the following detailed description of exemplaryembodiments and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter, which is regarded as the invention, is particularlypointed out and distinctly claimed in the claims at the conclusion ofthe specification. The foregoing and other objects, features, andadvantages of the invention are apparent from the following detaileddescription taken in conjunction with the accompanying drawings inwhich:

FIG. 1 is a top plan view of one embodiment of a washable diaper,showing an assembled inner liner system detachably coupled to an outerarticle, in accordance with an aspect of the present invention;

FIG. 2 is an enlarged cross-section view taken along the Line 2-2 of thewashable diaper in FIG. 1, in accordance with an aspect of the presentinvention;

FIG. 3 is a top plan view of another embodiment of the outer article,where the opposing side edges are configured to conform to the body ofthe wearer of the washable diaper, in accordance with an aspect of thepresent invention;

FIG. 4 is a top plan view of another embodiment of the outer article,where the opposing side edges are elasticized to conform to the body ofthe wearer of the washable diaper, in accordance with an aspect of thepresent invention;

FIG. 5 is an exploded perspective view of the washable diaper of FIG. 1,showing the outer article, the inner liner system that includes aflushable liner, one washable article, and one absorbent pad, inaccordance with an aspect of the present invention;

FIG. 6A is a top plan view of the inner liner system that includes theflushable liner and at least one washable article being aligned forassembly, in accordance with an aspect of the present invention;

FIG. 6B is a top plan view of the flushable liner and at least onewashable article, with one edge of the flushable liner folded over tocover the at least one washable article, in accordance with an aspect ofthe present invention;

FIG. 6C is a top plan view of the assembled inner liner system thatincludes the flushable liner and at least one washable article, alignedfor assembly with the outer article and with both edges of the flushableliner folded over to cover the at least one washable article, inaccordance with an aspect of the present invention;

FIG. 6D is an enlarged top plan view, showing the opening at one end ofthe assembled inner liner system created by aligning the openings of theflushable liner and at least one washable article, in accordance with anaspect of the present invention;

FIG. 7 is a perspective view of the washable diaper of FIG. 1, showingthe inner surface of the back end of the outer article and the backcompartment, illustrating the fastening mechanism detachably couplingone end of the inner liner system to the back end of the outer article,in accordance with an aspect of the present invention;

FIG. 8 is a frontal view of the washable diaper of FIG. 1 worn by aninfant, in accordance with an aspect of the present invention;

FIG. 9 is a back view of the washable diaper of FIG. 1 worn by aninfant, in accordance with an aspect of the present invention;

FIG. 10 is a top plan view of another embodiment of a washable diaper,showing an assembled inner liner system detachably coupled to an outerarticle, in accordance with an aspect of the present invention;

FIG. 11 is a perspective view of the washable diaper of FIG. 10, showingthe inner surface of the outer article including the first and backcompartments, in accordance with an aspect of the present invention;

FIG. 12 is a top plan view of the washable diaper of FIG. 10 showingelasticized side barriers and the interior of the outer article, inaccordance with an aspect of the present invention;

FIG. 13 is a top plan view of another embodiment of an outer article,where the opposing side edges are integral with the outer article andare not elasticized, in accordance with an aspect of the presentinvention;

FIG. 14 is an exploded perspective view of the washable diaper of FIG.10, showing an outer article, a inner liner system that includes atleast one flushable liner, at least one washable article, and at leastone absorbent pad, in accordance with an aspect of the presentinvention;

FIG. 15A-C are top plan views of the at least one flushable liner and atleast one washable article of the washable diaper of FIG. 10, with theat least one flushable liner being progressively applied to the at leastone washable article, in accordance with an aspect of the presentinvention;

FIG. 16 is an enlarged cross-section view taken along the line 16-16 ofthe washable diaper of FIG. 10, in accordance with an aspect of thepresent invention;

FIG. 17 is an enlarged cross-section view taken along the line 17-17 ofthe washable diaper of FIG. 10, in accordance with an aspect of thepresent invention;

FIG. 18 is a front view of the washable diaper of FIG. 10 worn by aninfant, in accordance with an aspect of the present invention;

FIG. 19 is a back view of the washable diaper of FIG. 10 worn by aninfant, in accordance with an aspect of the present invention;

FIG. 20 is a top plan view of another embodiment of an outer articleshowing a layer of the outer article being initially formed, inaccordance with an aspect of the present invention;

FIG. 21 is a top plan view of the washable diaper of FIG. 20 showing theouter article being further processed, in accordance with an aspect ofthe present invention; and

FIG. 22 is a top plan view of the washable diaper of FIG. 20 showing theouter article being still further processed.

DETAILED DESCRIPTION

The following detailed description of a washable diaper illustrates byway of example and not by way of limitation. While the detaileddescription is made in the context of a diaper, it is apparent that thepresent invention would also be suitable for feminine care products,incontinence garments, training pants, and the like. Generally stated,disclosed herein is an embodiment of a washable diaper, comprising of anouter article and an inner liner system. Further described herein is amethod of assembling an embodiment of the washable diaper.

One embodiment of a washable diaper 10, embodying the principles andconcepts of the present invention, is illustrated in FIGS. 1-9 anddescribed below. FIG. 1 shows washable diaper 10 that has beenassembled, comprising an outer article 20, and an inner liner system 40.

As illustrated in FIG. 5, one embodiment of washable diaper 10 may beassembled with at least one absorbent pad 70, at least one washablearticle 50, a liner member 60 and outer article 20. At least oneabsorbent pad 70 is fabricated from any absorbent material, includingbut not limited to, cotton, flannel, and organic cotton. At least oneabsorbent pad 70 may further be shaped to better suit the needs of malewearers or female wearers. In assembling washable diaper 10, at leastone absorbent pad 70 is inserted within at least one washable article50, through an opening 55 configured to accept at least one absorbentpad 70.

As seen in FIG. 5, at least one washable article 50 has a first end 51and a second end 52, and also includes an opening 53 located about firstend 51 and an opening 54 located about second end 52. Openings 53, 54are located on opposing ends of at least one washable article 50. Atleast one washable article 50 further comprises opening 55 that isconfigured to receive at least one absorbent pad 70. Opening 55 isdisposed on at least one washable article 50 and may be configured toextend longitudinally from first end 51 to second end 52 of washablearticle 50, and may be located in various positions, including on thefront side, back side, or either lateral sides of at least one washablearticle 50, so long as opening 55 can accommodate the insertion of atleast one absorbent pad 70. At least one washable article 50 istypically fabricated from any absorbent material, including, but notlimited to, cotton, flannel, and organic cotton.

As exhibited in FIGS. 6A-6C, at least one washable article 50, that mayhave at least one absorbent pad 70 placed within, is wrapped by orenclosed within liner member 60. Liner member 60, having a first end 61and a second end 62, has at least one opening 63 on first end 61 and atleast one opening 66 on second end 62. Liner member 60 is compliant,soft feeling, and non-irritant to the wearer's skin. Liner member 60 maybe fabricated from a liquid pervious material, including but not limitedto, rice paper, cellulose fibers, blend of rayon and cellulose fibersand any other liquid permeable hydrophobic fibrous materials that willallow liquid to readily penetrate through its thickness. Liner member 60may also be fabricated from a material that will wick moisture away fromthe wearer's skin. Liner member 60 may further still be fabricated froma material that is biodegradable and flushable through a regular toiletsystem. A person having ordinary skill in the art is aware of the typeof liquid pervious material that can be used to manufacture liner member60 so that it would be biodegradable and flushable. When liner member 60is fabricated from a liquid pervious, flushable material, it willfunction to contain non-liquid bodily excrements and allow for easydisposal via a regular septic/sewer system.

As shown in FIG. 6A, liner member 60 has a length that is approximatelythe same as at least one washable article 50 and width that is generallywider than at least one washable article 50. Liner member 60 further hasthree openings 63, 64, 65 on first end 61 and three openings 66, 67, 68on second end 62. As shown in FIG. 6C, assembled inner liner system 40has an opening 43 at the first end 41 and an opening 44 at the secondend 42. As shown in FIG. 6D, openings 63, 64, 65 on first end 61 ofliner member 60 are coaxially aligned with opening 53 on first end 51 ofat least one washable article 50 to form opening 43 (shown in FIG. 6C)at first end 41 inner liner system 40.

FIG. 5 shows inner liner system 40 being constructed of at least oneabsorbent pad 70 placed within at least one washable article 50 andliner member 60. Inner liner system 40 is then configured to detachablycouple to outer article 20 by aligning inner liner system 40 adjacent tothe inner surface 29 of outer article 20 and, by using the at least onefastening mechanism 31 disposed on the inner surface of the front end 21(shown in FIG. 1) and the at least one fastening mechanism 32 disposedon the inner surface of the back end 22 (shown in FIG. 7) of outerarticle 20.

As seen in FIG. 1, first end 41 of inner liner system 40 is aligned withfront end 21 and is positioned to be held within the front compartment23 of outer article 20. Front compartment 23 is configured to receivefirst end 41 of inner liner system 40 and at least one fasteningmechanism 31 detachably couples first end 41 of inner liner system 40 toouter article 20 by coupling opening 43. As also shown in FIG. 1, atleast one fastening mechanism 31 is located on front end 21 and isdisposed on the inner surface of front compartment 23 of outer article20 and may be constructed by using hook and loop fasteners, such as theVelcro® brand hook and loop fastener system, but at least one fasteningmechanism 31 may also be constructed by using a hook and eye, pin,button, snap button or clasp mechanisms.

As shown in FIG. 7, second end 42 of inner liner system 40 is alignedwith back end 22 and is positioned to be held within the backcompartment 24 of outer article 20. Back compartment 24 is configured toreceive second end 42 of inner liner system 40 and at least onefastening mechanism 32 detachably couples second end 42 of inner linersystem 40 to outer article 20. As also exhibited in FIG. 7, at least onefastening mechanism 32 is disposed on the inner surface of backcompartment 24 of outer article 20 and may be constructed using hook andloop fasteners, such as the Velcro® brand hook and loop fastener system,but at least one fastening mechanism 32 may also be constructed by usinga hook and eye, pin, button, snap button or clasp mechanisms.

As illustrated in FIGS. 1, 5 and 7, outer article 20 is configured withfront end 21 and back end 22, and the opposing side edges 25, 26. Outerarticle 20 may also include the opposing side barriers 27, 28, situatedon inner surface 29 of outer article 20 and positioned substantiallyparallel to opposing side edges 25, 26. As shown in FIGS. 1, 2, 5, and7, opposing side barriers 27, 28 may be elasticized.

FIGS. 1, 3, 4, 5 and 7 illustrate opposing side edges 25, 26 beingconfigured to conform to the legs of the wearer to maximize fit andminimize potential leakage. This configuration gives outer article 20 anhourglass-like silhouette, with back end 22 being wider than front end21 due to the extended portions 36, 37 of back end 22. Outer article 20has back compartment 24, extending perpendicular to opposing sides edges25, 26, that will allow extended portions 36, 37 to wrap around thewearer's body from the back side to the front side, as seen in FIG. 9.Outer article 20 also has front compartment 23, extending relativelyperpendicular to opposing side edges 25, 26, that will allow wrappingaround the wearer's body on the front side, as seen in FIG. 8.

In this embodiment of washable diaper 10, front compartment 23 and backcompartment 24 are fashioned as a pocket or enclosure like structure, asillustrated in FIGS. 1, 3, 4, 5, and 7, but front compartment 23 and/orback compartment 24 may be designed as a flap, a pouch, reinforced patchof material or reinforced strip of material.

Outer article 20, as shown in FIGS. 1, 3, 4, 5, and 7-9, may beconstructed using any material that will allow inner surface 29 (asshown in FIGS. 3, 4, 5 and 7) of outer article 20 to be liquidimpervious. Outer article 20 may be comprised of a single layer shellconstruct manufactured from a liquid impervious material, or liquidresistant material, including but not limited to nylon. Outer article 20may also be constructed using multiple layers of material, with onelayer being constructed of a liquid impervious layer. When outer article20 is made of multiple layers, a liquid impervious layer may be disposedas one of the inner layers. The outer-most layer may be manufacturedfrom any material, including but not limited to a breathable material.The outer-most layer may also be manufactured from any material thatwould be desirable, including for the purpose of increasing the comfortfor the wearer, and enhancing the aesthetics of washable diaper 10.

The fastening mechanisms 33, 34, disposed on extended portions 36, 37 ofback end 22 of outer article 20, as depicted in FIGS. 1, 3, 4, 5 and 7,are used to detachably couple to the front of outer article 20, whenwashable diaper 10 is worn, as shown in FIG. 8. Fastening mechanisms 33,34 as shown in FIGS. 1, 3, 4, 5 and 7, are hook and loop fasteners, suchas the Velcro® brand hook and loop fastener system, but fasteningmechanisms 33, 34 may also be one of hook and eye, pin, button, snapbutton, buckle, or clasp mechanisms.

FIG. 2 depicts a cross section of washable diaper 10 of FIG. 1, showingthe multiple layers that compose inner liner system 40. Typically, innerliner system 40 is constructed with at least one washable article 50,liner member 60 and at least one absorbent pad 70. Liner member 60completely surrounds at least one washable article 50. Opposing sidebarriers 27, 28 further secure inner liner system 40 in outer article20, so that inner liner system 40 does not shift or move when washablediaper 10 is worn and operate to enhance the containment and absorptionof urine and other bodily excrements.

FIGS. 3 and 4 show additional embodiments of outer article 20 ofwashable diaper 10. As illustrated in FIGS. 1, 3-5, and 7-9, opposingside edges 25, 26 of outer article 20 are configured to conform to thelegs of the wearer of washable diaper 10. Opposing side edges 25, 26 maybe elasticized, as shown in FIG. 4, or not, as illustrated in FIG. 3.The contoured configuration of opposing sides 25, 26 of outer article 20ensures the secure fit of washable diaper 10 and minimizes potentialleakage issues. Elasticized opposing side edges 25, 26 as seen in FIG.4, create a tighter fit on the wearer's legs (see FIG. 8) and provideenhanced protection against leakage.

FIGS. 6A-6C illustrate the method of assembly of liner member 60 and atleast one washable article 50. As shown in FIG. 6A, at least onewashable article 50 includes opening 53 on first end 51 and opening 54on second end 52. At least one washable article 50 is usually placed ontop of liner member 60 that has first end 61 and second end 62, withthree openings 63, 64, 65 on first end 61 and three openings 66, 67, 68on second end 62. First end 51 of at least one washable article 50 isaligned with first end 61 of liner member 60, and second end 52 of atleast one washable article 50 is aligned with second end 62 of linermember 60, so that middle opening 63, 66 of liner member 60 are alignedwith openings 53, 54 of at least one washable article 50.

As shown in FIGS. 6B and 6C, the width of liner member 60 is wrappedabout at least one washable article 50, so as to wholly surround atleast one washable article 50. When liner member 60 is wrapped about atleast one washable article 50, openings 64, 65 are aligned with opening63 on first end of liner member 61 and openings 67, 68 are aligned withopening 66 on second end of liner member 62, as seen in FIG. 6C.Openings 53, 63, 64, 65 are coaxially aligned to represent the compositeopening 43 on first end 41 of inner liner system 40 and openings 54, 66,67, 68 are aligned to represent the composite opening 44 on second end42 of inner liner system 40.

FIG. 6D depicts an enlarged view of the area identified by the circlenoted in FIG. 6C and shows the detailed view of opening 43 on first end41 of assembled inner liner system 40, that is created by aligningopening 53 on first end 51 of at least one washable article 50 andopenings 63, 64, 65 on first end 61 of liner member 60 (shown in FIG.6C). Composite opening 43 facilitates the ease of detachably couplinginner liner system 40 to outer article 20 using at least one fasteningmechanism 31, 32.

FIGS. 8 and 9 show washable diaper 10 being worn by an infant. As seenin FIG. 8, front end 21 of outer article 20 is configured to fit on thefront of the infant, with back end 22 of outer article 20 covering theinfant's bottom (see FIG. 9). Fastening mechanism 35 is located on outersurface 30 of front end 21 of outer article 20. Extended portions 36, 37of back end 22 of outer article 20 are wrapped around the infant todetachably couple to front end 21 of outer article 20. Fasteningmechanism 35 as shown in FIG. 8 depicts a strip of one part of the hookand loop fastener. Additionally, fastening mechanism 35 may be made ofseveral latching mechanisms including hook and eye, pin, button, snapbutton or clasp constructs.

FIGS. 10-12 and 14-19 show another exemplary illustrated embodiment of awashable diaper generally indicated by the reference numeral 110.Exemplary washable diaper 110 is similar to washable diaper 10 describedabove in connection with FIGS. 1-9, and therefore like referencenumerals preceded by the number “1” are used to indicate like elements.The description above with reference to exemplary washable diaper 10 maytherefore apply to particular components, systems, features or the likeof exemplary washable diaper 110 and is not repeated hereinafter forbrevity. Like exemplary illustrated washable diaper 10, exemplaryillustrated washable diaper 110 includes an exemplary outer article 120and an exemplary inner liner system 140.

As illustrated in FIG. 10, one exemplary embodiment of washable diaper110 may be an assembly of an outer article 120 and an inner liner system140. The inner liner system 140 may be any system or component that iscapable of mating with the outer article 120 such that the washablediaper 110 can be worn by a user. As shown best in FIG. 14, the innerliner system 140 may include at least one of an absorbent pad 170, awashable article 150 and a liner member 160. As discussed further belowwith respect to FIGS. 14-16, in some embodiments the at least onewashable article 150 may include an opening 155 in communication with acavity 154. The opening 155 and cavity 154 may be configured to acceptand retain at least one absorbent pad 170 therethrough/therewithin atleast when the inner liner system 140 is assembled with the outerarticle 120 to form the washable diaper 110. As also discussed furtherbelow, the at least one washable article 150 may be configured (e.g.,the opening 155 and cavity 154 may be configured) such that the at leastone absorbent pad 170 is easily removable, such as being consistentlyremoved during a wash cycle of a typical washing machine.

As shown in FIGS. 10-12, 14 and 17, the outer article 120 may includefront compartment, flap, pouch or pocket 123 at a front end 121 and asecond compartment, flap, pouch or pocket 124 at a second end 122. Thefirst and second compartment 123, 124 may be formed, at least in part,by a first member, component, portion or material 185 and a secondmember, component, portion or material 186 adjacent or laying over thefirst member 185. In this way, first and second compartment 123, 124 areformed by the space or area between the first and second member 185,186. The front and back ends 121, 122, may also include at least onestiffening member or configuration such that the front and back ends121, 122, and the portions proximate thereto, are relatively stiff ascompared to portions without the stiffening members and, thereby, areprevent from folding or otherwise deforming into a “closed” orientation.

In some embodiments, the first member 185 may be a portion of the innerlining or material that forms the inner surface 129 of the outer article120, as shown in FIGS. 10-12, 14, 16 and 17. As described above, theinner surface 129 may be substantially liquid impervious. In such anembodiment, the inner surface 129 may span substantially along theentire length of the outer article 120. In contrast, the second member186 of the first and second compartments 123, 124 may be substantiallyaligned along the first and second ends 121, 122, respectively, of theinner surface 129 (and therefore the outer article 120 itself), but mayonly extend partially towards the longitudinal center of the outerarticle 120. The second portion 186 may therefore be the portion of theinner surface 129 that lies adjacent to the first portion 185. In thisway, the first and second compartments 123, 124 may be positionedadjacent the first and second ends 121, 122 of the outer article 120,respectively, and a medial portion 139 of the inner surface 129 of theouter article may be void (or not covered by the second portion 186), asshown in FIGS. 11, 12 and 14.

The first and second compartment 123, 124 may be include an opening thatfaces the medial portion 139 of the outer article 120 (and the innersurface 129), as shown in FIGS. 10-12 and 14. However, besides theopening or passageway facing the medial portion 139 of the outer article120, the first and second compartment 123, 124 may be operably coupledsuch that the first and second compartments 123, 124 formed therebetweenis substantially “closed”. In the exemplary illustrated embodiment, thefirst and second compartment 123, 124 are “closed” (apart from themedial openings) such that they are substantially liquid impervious.

As shown best in FIGS. 10 and 11, the first and second compartment 123,124 (e.g., the first and second portions 185, 186) may be “sealed”(except for the medial facing openings), at least in part, by banding180. As illustrated in FIGS. 10-12 and 16-19 and described furtherbelow, banding 180 may be a substantially liquid imperious material,assembly or the like that is applied over a seam, joint, edge or thelike. For example, in some embodiments the banding 180 may besubstantially liquid impervious fabric material. The banding 180 may beapplied such that the banding 180 seals a joint seam, edge or the like,such as a creating a substantially liquid impervious seal. In someembodiments, banding 180 may be applied over a seam, joint, edge or thelike by stitching, such as being stitched with substantially non-wickingthread via a needle. In some exemplary embodiments, the non-wickingthread may be a polyester thread and the needle may be a ball needle. Inthis manner, banding 180 may be applied to seams, edges, joints or thelike of the outer article 120, including any such connections betweenthe first and second portions 185, 186 of the first and secondcompartments 185, 186 to substantially prevent liquid from migratingthrough the outer article 120 via a seam, joint, edge or the liketherein. In other embodiments, seams, edges, joints or the like of theouter article 120 (or any other component) may be “sealed” in anotherknown manner such that they are substantially liquid impervious.

In the illustrated exemplary embodiment best shown in FIGS. 10-12 and14, the first and second compartment 123, 124 of the outer article 120extend substantially along the entire width of the outer article 120 andinclude banding 180 applied to the first and second portions 185, 186 onthe opposing side edges 125, 126 of the outer article 120 (and thereforethe first and second compartment 123, 124). In some embodiments, thebanding 180 itself is substantially liquid impervious, and the banding180 is applied to the opposing side edges 125, 126 of the first andsecond portions 185, 186 in a manner that seals the opposing side edges125, 126 of the first and second portions 185, 186 such that liquid issubstantially prevented from migrating therethrough. In this way, theopposing side edges 125, 126 of the first and second compartment 123,124 may be substantially liquid impervious. For example, the banding 180may be sewn over the opposing side edges 125, 126 of the first andsecond portions 185, 186 with non-wicking thread (such as with a ballneedle).

As described above, the first and second members 185,186 of the firstand second compartments 123, 124 may be substantially aligned along thefirst and second ends 121, 122, of the outer article 120. For example,if the first and second members 185,186 are separate and distinctcomponents, they may be substantially aligned along the first and secondends 121, 122, of the outer article 120. In such an embodiment, thefirst and second ends 121, 122 of the first and second members 185,186may be coupled to one another, such as sealed to one another. Forexample, as shown in the illustrated exemplary embodiment of the outerarticle 120 in FIGS. 10, 11, 14, 16 and 17, the first and second ends121, 122 of the first and second members 185,186 of the first and secondcompartment 123, 124 may include banding 180. In some such embodiments,the banding 180 itself is substantially liquid impervious, and thebanding 180 is applied to the first and second ends 121, 126 of thefirst and second portions 185, 186 in a manner that seals the first andsecond ends 121, 122 of the first and second portions 185, 186 such thatliquid is substantially prevented from migrating therethrough. In thisway, the first and second ends 121, 122 of the first and secondcompartment 123, 124 may be substantially liquid impervious. Forexample, the banding 180 may be sewn over the opposing first and secondends 121, 122 of the first and second portions 185, 186 with non-wickingthread (such as with a ball needle). In some embodiments, the mechanismthat couples the banding 180 to the outer article 120 also acts tocouple the first and second portions 185, 186 to one another. Forexample, in embodiments wherein the banding 180 is applies to the firstand second ends 121, 122 via thread, the thread may also act to couplethe first and second portions 185, 186 to one another (i.e., the threadmay stitch the first and second portions 185, 186 at the first andsecond ends 121, 122.

In some embodiments of the outer article 120, such as the illustratedexemplary embodiment of FIGS. 10-12 and 14, the first and second members185,186 of the first and second compartment 123, 124 may be integral,monolithic, one-piece or the like. In such an embodiment, the first andsecond members 185,186 may be substantially liquid impervious (e.g., theinner surface 129 may be substantially liquid impervious) and foldedover upon themselves at the first and second ends 121, 122. The “foldline” between the first and second members 185,186 may thereby define,at least in part, the first and second ends 121, 122 of the first andsecond compartment 123, 124 (and therefore outer article 120 itself).Also, the “fold line” between first and second members 185,186 maydefine the bottom of the first and second compartment 123, 124 whichopposes the openings facing the medial portion 139 of the outer article120. In this way, the first and second ends 121, 122 may besubstantially liquid impervious. However, for aesthetics and/or wearprevention, in the some embodiments the first and second members 185,186of the first and second compartment 123, 124 may be integral and the“fold line” between first and second members 185,186 may include banding180, as shown best in FIGS. 10-12 and 14. For example, the entireoutline or outer edges of the outer article 120 may include banding 180,such as singled piece or potion of banding sewn over the entire outlineor outer edges of the outer article 120.

As shown in FIG. 10, the first end 141 of inner liner system 140 may bealigned with the front end 121 of the washable article 120 andpositioned within the front compartment 123. To this end, the frontcompartment 123 may configured to receive the first end 141 of the innerliner system 140 therein. For example, the second member 186 of thefront compartment 123 may extend along the width of the outer article120 (a direction extending between the opposing side edges 125, 126 ofthe washable article 120) a sufficient distance such that the width ofthe inner liner system 140 is substantially the same or smaller. In theexemplary illustrated embodiment best shown in FIG. 10, the width of thesecond member 186 of the front compartment 123 is about equal to thewidth of the outer article 120 and the first member 185 and greater thanthe width of the inner liner system 140, as indicated by the dashedlines representing the outer edges of the inner liner system 140 in thefirst compartment 123. Similarly, in the illustrated embodiment thesecond member 186 of the front compartment 123 extends along the lengthof the outer article 120 (a direction extending between the first andsecond ends 121, 122 of the washable article 120) a distance such that arelatively substantial portion of the length of the inner liner system140 can be positioned within the first compartment 123, as indicated bythe dashed lines representing the outer edges of the inner liner system140 in the first compartment 123 in FIG. 10. In this way, the first end141 of the inner liner system 140 may be positioned substantially withinthe first compartment 123 such that any liquid flowing through, orforced from, the first end 141 of the inner liner system 140 (or aportion adjacent thereto) becomes trapped or held within thesubstantially liquid impervious first compartment 123.

The second compartment 186 of the outer article 120 may be configuredsubstantially similar to the first compartment 185 of the outer article120, such as described above. Specifically, as shown in FIG. 10 thesecond end 142 of inner liner system 140 may be aligned with the secondend 122 of the washable article 120 and positioned within the backcompartment 124. To this end, the back compartment 124 may configured toreceive the second end 142 of the inner liner system 140 therein. Forexample, the second member 186 of the back compartment 124 may extendalong the width of the outer article 120 (a direction extending betweenthe opposing side edges 125, 126 of the washable article 120) asufficient distance such that the width of the inner liner system 140 issubstantially the same or smaller. In the exemplary illustratedembodiment best shown in FIG. 10, the width of the second member 186 ofthe back compartment 124 is about equal to the width of the outerarticle 120 and the first member 185 and greater than the width of theinner liner system 140, as indicated by the dashed lines representingthe outer edges of the inner liner system 140 in the second compartment124. Similarly, in the exemplary illustrated embodiment the secondmember 186 of the second compartment 124 extends along the length of theouter article 120 (a direction extending between the first and secondends 121, 122 of the washable article 120) a distance such that arelatively substantial portion of the length of the inner liner system140 can be positioned within the second compartment 124, as indicated bythe dashed lines representing the outer edges of the inner liner system140 in the second compartment 124 in FIG. 10. In this way, the secondend 142 of the inner liner system 140 may be positioned substantiallywithin the second compartment 124 such that any liquid flowing through,or forced from, the second end 142 of the inner liner system 140 (or aportion adjacent thereto) becomes trapped or held within thesubstantially liquid impervious second back compartment 124.

As shown in FIGS. 11, 12 and 14 with the inner liner system 140 notassembled with the outer article 120, the inner surface 129 may besubstantially void and the first and second compartments 123, 124 mayinclude at least one fastening mechanism 131 positioned therein. InFIGS. 11, 12 and 14, the at least one fastening mechanism 131 is shownin dashed lines representing its positioning under second member 186.FIG. 12 also shows the second member 186 of the first and secondcompartments 123, 124 partially cut away to reveal the at least onefastening mechanism 131 beneath. The at least one fastening mechanism131 may be coupled to the outer article 120 by any means, and may takethe form of any known fastening mechanism in the art. As non-limitingexample, the at least one fastening mechanism 131 may be at least onehalf or mate of a hook and loop fastener, such as a Velcro® brand hookand loop fastener system, a hook and eye fastener, pin fastener, buttonfastener, snap button or clasp mechanisms, or the like. In theillustrated exemplary embodiment, the at least one fastening mechanism131 is one half or the mate of a press, spring or snap button that facesaway from the first portion 185 and toward the second portion 186.Further, the number and positioning of the at least one fasteningmechanism 131 may vary. For example, the at least one fasteningmechanism 131 may or may not be positioned within the first and secondcompartments 123, 124. As another example, multiple fastening mechanisms131 may be provided, such as being provided within the first and secondcompartments 123, 124. Still further, at least one fastening member 131may be provided in one of the first and second compartments 123, 124.The at least one fastening mechanism 131 may be configured to detachablycouple the inner lining system 140 to the outer article 120. Morespecifically, the at least one fastening member 131 may be configured todetachably couple the inner liner system 140 to the outer article 120such that the first end 141 of the inner liner system 140 and anadjacent portion of the inner liner system 140 is positioned andselectively secured within the first or front compartment 123, and suchthat the second end 142 of the inner liner system 140 and an adjacentportion of the inner liner system 140 is positioned and selectivelysecured within the second or back compartment 124.

In the illustrated exemplary embodiment, the first or front and secondor back compartments 123, 124 include a pair of fastening mechanisms 131spaced along the width of the compartments 123, 124, as shown in FIGS.10-12, 14 and 17. As shown best by the cutaway view of FIG. 12, theillustrated exemplary outer article 120 includes a pair of fasteningsupport members 182 coupled to the outer article 120, and each fasteningsupport member 182 includes a fastening mechanism 131 coupled theretoand positioned within the respective first or second compartment 123,124. In some embodiments, the fastening support members 182 may beflexible, and may extend from the respective first or second ends 121,122. For example, the fastening support members 182 may include fabric,at least in part, and may be secured to the outer article 120 at therespective first or second ends 121, 122. In some such embodiments, themechanism that couples the first and second portions 185, 186 to oneanother also couples the fastening support members 182 to the outerarticle 120. For example, in the illustrated exemplary embodiment shownbest in FIG. 12 the first and second portions 185, 186 of the first andsecond compartments 123, 124 are coupled to one another (besides beingintegral) by banding 180 being stitched over the first and secondmembers 185, 186 at the first and second ends 121, 122, respectively,and the fastening support members 182 are positioned between the firstand second portions 185, 186 and aligned at the first and second ends121, 122 such that the stitching also passes through the fasteningsupport members 182. However, in other outer article 120 embodiments thefastening support members 182 may be coupled to the outer article my anyknown mechanism or method known in the art. Further, the fasteningsupport members 182 may not be provided, or may not be provided in thefirst and second compartments 123, 124. For example, the fasteningmechanism 131 may be provided on the outer article 120 by any otherknown mechanism or method, such as being coupled to the inner surface129 of the outer article, such as to the inner surface 129 of the firstor second members 185, 186.

As illustrated best in FIGS. 10-12, 14 and 16, the outer article 120 mayinclude first and second opposing side barriers 127, 128 at the medialportion 139 of the outer article 120. The first and second side barriers127, 128 may extend from the first and second opposing side edges 125,126 of the outer article 120, respectively, in a direction extendingfrom the outer surface 130 toward the inner surface 139 (i.e., towardthe wearer). The opposing side barriers 127, 128 may thereby furthersecure the inner liner system 140 in the outer article 120 so that innerliner system 140 does not shift or move when washable diaper 110 isworn. The opposing side barriers 127, 128 may thereby also operate toenhance the containment of urine and other bodily excrements in theouter article 120, and consequently operate to enhance the absorption ofbodily excrements by the inner liner system 140. In the illustratedexemplary embodiment, the side barriers 127, 128 are distinct ordiscrete components coupled to the outer article 120. In some suchembodiments, the side barriers 127, 128 may be panels tapered at one orboth ends with an inner curved surface coupled to the opposing sideedges 125, 126 of the inner surface 129, as shown best in FIGS. 11 and20-22 and described further below. The side barriers 127, 128 may becoupled to the opposing side edges 125, 126 of the outer article 120,respectively, by banding 180. For example, as shown best in thecross-sectional view of the outer article 120 of FIG. 10 in FIG. 16, thecurved edge of the side barriers 127, 128 may in abutment with the innersurface 129 of the outer article 120 and banding 180 may be stitched 184over the outer article 120. More specifically, stitching 184 may passthrough an inner portion of the banding 180, the respective side barrier127, 128, the inner surface 129 and an outer portion of the banding 180as shown in FIG. 16. If the outer article 120 includes one or moreadditional layers above the inner layer 129, the stitching 184 may passthrough the additional layers as well.

The way in which the side barriers 127, 128 are attached to the outerarticle 120 may tend to force or encourage the side barriers 127, 128 toextend away from the inner surface 129 toward the body of a wearer,thereby providing a curved shape to the outer article 120 such that themedial portion 139 of the outer article forms a depression or cuppedregion. For example, the stitching 184 and banding 180 configurationshown in the cross-sectional view of FIG. 16 may act to force the outeredges of the side barriers 127, 128 to extend away from the innersurface 129 to form a “U” shape. By extending away from the innersurface 129 of the outer article, the side barriers 127, 128 may providea space between the wearer and the inner surface 129 for the inner linersystem 140 and the anatomy of the wearer so that the outer edges of theside barriers 127, 128 abut and conform to the wearer and preventleakage.

The side barriers 127, 128 may include an elasticized member or portion188 which may additionally contribute to the positioning of the sidebarriers 127, 128 away from the inner surface 129 of the outer article120. Further, the elasticized member or portion 188 of the side barriers127, 128 may tend to cup or bow the outer article 120 in the lengthdirection from the front or first side 121 to the second or back end122, as shown best in FIG. 11. The cupping or bowing of the outerarticle 120 in the length direction may enhance the fit and comfort ofthe washable diaper 110. For example, the elasticized side barriers 27,28 may be configured to conform to the legs of the wearer and minimizepotential leakage out from within the interior of the outer article 120.

In some embodiments, as shown in FIGS. 10-12, 14 and 16 the elasticizedmember or portion 188 of the side barriers 127, 128 may be the outeredges of the side barriers 127, 128. The elasticized member or portion188 of the side barriers 127, 128 may take any form such that in aneutral position the elasticized member or portion 188 is capable ofbeing stretched at least lengthwise so the outer article 120 “flattens”out. Stated differently, the elasticized member or portion 188 of theside barriers 127, 128 may take any form such that in a neutral positionthe side barriers 127, 128 tend to pull or form the outer article into acupped or bowl shape (see FIG. 11). As shown in FIG. 11, the exemplaryelasticized member or portion 188 of the exemplary illustrated sidebarriers 127, 128 is an elasticized member 188 coupled to the outeredges of the side barriers 127, 128. Further, as shown in FIGS. 10-12and 14 the exemplary elasticized member or portion 188 of the exemplaryillustrated side barriers 127, 128 is coupled to their respective sideedge 125, 126 of the inner layer 129 as opposing ends.

In some alternative embodiments, the outer article 120 may not includeseparate and distinct side barriers 127, 128, such as exemplary outerarticle 220 illustrated in FIG. 13. In some such embodiments, the innerlayer or surface 229 of the outer article 220 may include substantiallythe same shape and size as compared to an outer article that includesseparate and distinct side barriers coupled to opposing sides. In someembodiments however, the outer article 220 may be shaped and sizedsubstantially similar to the outer profile and size of an outer articlethat includes separate and distinct side barriers coupled to opposingsides. In this way, the side barriers may be in essences integral withthe outer article, such as integral with the inner layer or surface 229and the outer article 220 retains the advantages of the side barriers,as shown in FIG. 13. As also shown in FIG. 13, in some such embodimentsthe outer article 220 may include banding 280 about its side portionsalong an internal portion of the outer article in locations whereseparate and distinct side barriers would be attached to the outerarticle (such as to the inner surface or portion 229). In this way, theintegral side barriers 227, 228 may tend to extend away from the innerlayer or surface 229 and toward the user to include the advantageousfit, leakage and aesthetic properties or benefits described above withrespect to outer article 120 and side barriers 127, 128.

FIGS. 10-12, 14 and 19 best illustrate the shape of the exemplary outerarticle 120. The shape and size of the outer article 120, and thereforethe washable diaper 110 in general, may be configured such that thewashable diaper 110 surrounds or otherwise conforms to the legs andwaist of the wearer to maximize fit and minimize potential leakage. Forexample, the exemplary illustrated outer article 120 is configured witha generally hourglass-like silhouette with the front and back ends 121,122 including first and second opposing extended portions 136, 137,respectively, being wider than the medial portion 139. In theillustrated exemplary embodiment, the first extended portions 136, 137at the back end 122 of the outer article 120 are capable of extending orwrapping around the user's body or waist when worn, as shown in FIG. 18.The second extended portions at the second or back end 122 of the outerarticle 120 may extend further than the first extended portions 136 atthe first or front end 121 (i.e., the second extended portions 137 maybe wider than the first extended portions 136), as shown best in FIGS.10-12 and 14. In some such embodiments, when the washable diaper 110 isworn the second extended portions 137 of the back end 122 of the outerarticle 120 may wrap around the user's waist and over the outer surfaceof the first extended portions 136 and the portion extendingtherebetween (at least in part).

In order to removably couple the second extended portions 137 to anotherportion of the outer article 120, such as when the washable diaper 110is being worn by a user and thereby couple the washable diaper 110 tothe user, the second opposing extended portions 137 may include firstfastening mechanisms 133, as shown in FIGS. 10-12, 14 and 17. The firstfastening mechanisms 133 of the second extended portions 137 may be anyknown fastening mechanism capable of removably coupling the secondextended portions 137 with another portion of the outer article 120,such as a portion of the outer surface or layer 130. In some embodimentsthe first fastening mechanisms 133 of the second extended portions 137may be one part of a multiple-part fastening mechanism, such as one partof a multiple-part fastening mechanism that is configured to mate withanother part of the multiple-part fastening mechanism positioned onanother portion of the outer article 120. For example, the firstfastening mechanisms 133 of the second extended portions 137 may be onepart or member of a hook and loop fastener, such as a Velcro® brand hookand loop fastener system, a hook and eye fastener, pin fastener, buttonfastener, snap button or clasp mechanisms, or the like. In otherembodiments, the first fastening mechanisms 133 of the second extendedportions 137 may be a single-part fastening mechanism. In theillustrated exemplary embodiment best shown in FIGS. 10-12, 14, 17 and18, the first fastening mechanisms 133 comprises one part of a hook andloop fastener and extend from the second extended portions 137 out pastthe side edges 125, 126 of the outer article. As explained furtherbelow, the one or more first fastening mechanisms 133 may be configuredto removably mate, couple or attach to one or more second fasteningmechanism 134 that is provided on another portion of the outer article120, such as on the outer surface 130 and adjacent the back end 122.

In some alternative embodiments (not shown), the first fasteningmechanisms 133 may include multiple fastening mechanisms and anextension member therebetween, at least one of the multiple fasteningmechanisms for mating with the one or more second fastening mechanism134 of the outer article 120. For example, the first fasteningmechanisms 133 may include a fastening mechanism provided on theextended portions 137, and an extension member including a fasteningmechanism proximate one end of the extension member for removablycoupling with the fastening mechanism provided on the extended portions137 and another fastening mechanism proximate another end of theextension member for removably coupling with a second fasteningmechanism 134 provided on the first extended portions 136 or theportions of the outer article 120 thereabout (such as on the outersurface or layer 130 of the first extended portions 136 and/or theportion of the outer surface 130 of the outer article 120 extendingbetween the first extended portions 136 and adjacent the front end 121).In some such embodiments, the fastening mechanism provided on theextended portions 137 of the first fastening mechanisms 133 and thesecond fastening mechanism 134 may also be configured to removablecouple to one another. In such an embodiment, the first fasteningmechanisms 133 may allow the outer article 120, and therefore thewashable diaper 110, to be worn by both small and large user's becausethe extension member may or may not be used. Stated differently, in suchan embodiment the fastening mechanism provided on the extended portions137 of the first fastening mechanisms 133 and the second fasteningmechanism 134 may be directly removably coupled (without the use of theextension member) to accommodate and removably coupled the washablearticle 120 (and therefore the washable diaper 110) to a relativelysmall user, or the extension member may be removably coupled between thefastening mechanism provided on the extended portions 137 of the firstfastening mechanisms 133 and the second fastening mechanism 134 toaccommodate and removably coupled the washable article 120 (andtherefore the washable diaper 110) to a relatively large user.

The second extended portions 137 may also include another fasteningmechanism, such as third fastening mechanisms 133B shown in FIGS. 10-12,14 and 17. The third fastening mechanisms 133B may be any knownfastening mechanism. The third fastening mechanism may or may not bedeposed or operably attached to the second extended portions 137 of theinterior surface 129. The third fastening mechanisms 133B of the secondextended portions 137 may be one part of a multiple-part fasteningmechanism, such as one part of a multiple-part fastening mechanism thatis configured to mate with another part of the multiple-part fasteningmechanism. For example, in the illustrated exemplary embodiment thethird fastening mechanisms 133B of the second extended portions 137 maybe configured to mate with the first fastening mechanisms 133 on thecorresponding second extended portions 137. As the first fasteningmechanisms 133 of the second extended portions 137 of the exemplaryillustrated embodiment are one part of a hook and loop fastener, thethird fastening mechanisms 133B may be the other part of the hook andloop fastener such that the first and third fastening mechanisms 133,133B are capable of removably mating or coupling. In this manner, forexample, each second extended portion 137, first fastening mechanism 133or third fastening mechanism 133B may be deformed such that the firstand third fastening mechanisms 133, 133B lie over one another and,thereby, removably couple or attach to one another. As is known in theart, such a configuration may be advantageous if the first fasteningmechanisms 133 are configured such that they tend to attach or couplewith other portions of the washable diaper 120 or other clothes,fabrics, fastening mechanisms, etc. For example, if the first fasteningmechanisms 133 are the hook portion of a hook and loop fastener, thefirst fastening mechanisms 133 may tend to attach or couple to otherportions of the washable diaper 110 or other fabrics when the washablediaper 110 is not worn, such as when the outer article 120 is beingwashed. In such a configuration, however, the first and third fasteningmechanisms 133, 133B may be mated or coupled such that the firstfastening mechanisms 133 (or third fastening mechanisms 133B) areblocked-off or otherwise rendered incapable of coupling to otherportions of the washable diaper 110 or other fabrics, clothes fasteningmechanisms, etc.

In some such embodiments, the outer surface of the first extendedportions 136, or portions of the outer article 120 thereabout (such ason the outer surface or layer 130 of the outer article 120 extendingbetween the first extended portions 136 and adjacent the front end 121)may include one or more second fastening mechanism 134, as shown in FIG.18. The at least one second fastening mechanism 134 may be configured toremovably couple with the first fastening mechanisms 133 of the secondextended portions 137, such as when the second extended portions 137 arewrapped around a users waist and over the first extended portions 136,as shown in FIG. 18. For example, the at least one second fasteningmechanism 134 may be one part of a multiple-part fastening mechanism,such as one part of a multiple-part fastening mechanism that isconfigured to mate with another part of the multiple-part fasteningmechanism. In the illustrated exemplary embodiment the at least onesecond fastening mechanism 134 is configured to removably mate, coupleor otherwise attach to the first fastening mechanisms 133 on the secondextended portions 137. As the first fastening mechanisms 133 of thesecond extended portions 137 of the exemplary illustrated exemplaryembodiment of the outer article 120 are one part of a hook and loopfastener, the at least one second fastening mechanism 134 may be theother part of the hook and loop fastener such that the first and secondfastening mechanisms 133, 134 are capable of removably mating, attachingor coupling.

The at least one second fastening mechanism 134 may further beconfigured such that the first fastening mechanisms 133 may couple tothe portion of the outer surface or layer 130 adjacent the front end 121of the outer article 120 in different locations, and thereby accommodatedifferent sized users, fits or tightness/looseness preferences of thewashable diaper 110. For example, the at least one second fasteningmechanism 134 may include several parts of a multiple-part fasteningmechanism that are configured to mate with the first fasteningmechanisms 133 positioned in different locations on the outer surface orlayer 130 of the outer article 120. As another example, as shown in FIG.18, the at least one second fastening mechanism 134 may be sized andshaped to expand over a region of the outer surface or layer 130adjacent the front end 121 of the outer article 120, such as arelatively large portion of one part of a hook and loop fastener (i.e.,a relatively large portion of hooks or loops). As the first fasteningmechanisms 133 of the second extended portions 137 of the exemplaryillustrated exemplary embodiment of the outer article 120 are one partof a hook and loop fastener, the at least one second fastening mechanism134 may be a relatively large portion of the other part of the hook andloop fastener such that the first fastening mechanisms 133 are capableof removably mating, attaching or coupling to the second fasteningmechanism 134 in a variety of location and orientations, as indicated bythe dashed outlines of the first fastening mechanisms 133 in FIG. 18. Inthis way, the second extended portions 137 may be extended over thefirst second extended portions 136 and the front portion of the outerarticle 120 to differing extends based on the size or preference of theuser.

As illustrated in FIGS. 11, 17 and 18, the second extended portions 137may include fourth fastening mechanisms 135 positioned on the outersurface or layer 130 of the outer article 120. For example, the fourthfastening mechanisms 135 may be sized and shaped substantially similarto the first fastening mechanisms and attached directly to thecorresponding opposing side of the second extended portions 137 of theouter article 120 (i.e., the outer side 130 as opposed to the inner side129). The fourth fastening mechanisms 135 may be any known fasteningmechanisms. The fourth fastening mechanisms 135 of the second extendedportions 137 may be one part of a multiple-part fastening mechanism,such as one part of a multiple-part fastening mechanism that isconfigured to mate with another part of the multiple-part fasteningmechanism. For example, in the illustrated exemplary embodiment thefourth fastening mechanisms 135 of the second extended portions 137 maybe configured to mate with the first fastening mechanisms 133. As thefirst fastening mechanisms 133 of the second extended portions 137 ofthe exemplary illustrated embodiment are one part of a hook and loopfastener, the fourth fastening mechanisms 135 may be the other part ofthe hook and loop fastener such that the first and fourth fasteningmechanisms 133, 135 are capable of removably mating or coupling.

In this manner, for example, when the washable diaper 100 is worn andthe outer article 120 is wrapped around the user's waist and legs, thesecond extended portions 137 may overlap the first extended portions 136and the portion of the outer surface 130 extending between the firstextended portions 136 such that one first fastening mechanisms 133completely or fully couples to the at least one second fasteningmechanism 134 and the other of the first fastening mechanisms 133partially or fully overlaps it. Such a configuration may result from auser being relatively small as compared to the size of the washablediaper 110. In such a scenario, the “overlapping” first fasteningmechanism 133 may partially removably couple to the at least one secondfastening mechanism 134 and partially removably couple to the firstfastening mechanism 133 that is completely or fully coupled to the atleast one second fastening mechanism 134. In this manner, the fourthfastening mechanisms 135 may provide the outer article 120 with greaterflexibility or use with differing sized users.

Turning to the inner liner system 140, as shown in FIGS. 14-17 the innerliner system 140 may include at least one washable article 150, at leastone liner member 160 and at least one absorbent pad 170. In somealternative embodiments of the washable diaper 110, however, anabsorbent pad 170 may not be provided in the washable article 150. Theat least one washable article 150 may include any material capable ofabsorbing liquid. For example, the at least one washable article 150 inthe illustrated embodiment is made from a sewn, liquid absorbentmaterial, such as a hemp, cotton, flannel or a micro fiber fabric. Asshown best in FIGS. 14-15C and 16, the at least one washable article 150may include an opening 155 in communication with a cavity 154. Theopening 155 and cavity 154 may be configured to accept and retain atleast one absorbent pad 170 therethrough/therewithin at least while theinner liner system 140 is assembled with the outer article 120 to formthe washable diaper 110. The exemplary opening 155 and cavity 154 ofexemplary illustrated washable article 150 may be formed by the washablearticle 150 and extend longitudinally from a first end 151 to second end152 thereof. The opening 155 may be located in various positions,including on the front side, back side, or either lateral sides of atleast one washable article 150 and of any size and shape, so long asopening 155 can accommodate the insertion of at least one absorbent pad170 within the and cavity 154. For example, the longitudinal length ofthe opening 155 may or may not be longer than the longitudinal length ofthe at least one absorbent pad 170. To that end, the cavity 154 incommunication with the opening 155 may be in any position within thewashable article 150 and may be any size and shape, so long at least oneabsorbent pad 170 can be positioned therewithin via the opening 155. Inthe illustrated exemplary embodiments of the washable article 150, thelongitudinal lengths of the opening 155 and the cavity 154 are at leastabout 80% the longitudinal length of the least one absorbent pad 170.

In some embodiments of the washable diaper 110 that include at least oneabsorbent pad 170, the at least one absorbent pad 170 may include atleast one axis of substantial symmetry, such as the exemplaryillustrated absorbent pad 170 shown best in FIG. 14. In such exemplaryembodiments, the use, advantages characteristics or other performancemetrics of the at least one absorbent pad 170 may not be affected by theorientation of the at least one absorbent pad 170 along the axis whenpositioned within the washable article 150. In some embodiments,however, the at least one absorbent pad 170 may be shaped or otherwiseconfigured such that its orientation within the washable article 150 mayaffect the performance of the at least one absorbent pad 170. In someembodiments, the at least one absorbent pad 170 may be configuredspecifically for use with either male or female users. For example, theat least one absorbent pad 170 may be shaped differently for use witheither male or female users. In other embodiments, the at least oneabsorbent pad 170 may be the same for both male and female users.

Similarly, in some embodiments the cavity 154 of the washable article150 and/or the at least one absorbent pad 170 may be configured suchthat the absorbent pad 170 is positioned within the washable article 150such that when the inner liner system 140 is coupled to the outerarticle 120 the absorbent pad 170 is positioned within the medialportion 139 of the outer article 120, such as being positioned withinthe medial portion 139 of the outer article 120 in specific positionsfor use with either male or female users.

In some embodiments, the size, shape, orientation and materialproperties of the at least one absorbent pad 170 and the washablearticle 150, including the opening 155 and cavity 154 thereof, may beconfigured such that the at least one absorbent pad 170 tends to easilybecome disengaged from the cavity 154 through the opening 155 when theinner liner system 140 is not assembled with the outer article 120 orthe washable diaper 110 is worn. For example, the at least one absorbentpad 170 and the washable article 150 may be configured such that whenthe washable article 150 is removed from the outer article 120 and theother components of the inner liner system 140, and washed during atypical wash cycle of a typical washing machine, the at least oneabsorbent pad 170 becomes dislodged from within the washable article150. In this way, the at least one absorbent pad 170 may advantageouslynot need to be handled or otherwise manually removed from the washablearticle 150, such as when the at least one absorbent pad 170 andwashable article 150 are soiled.

The at least one washable article 150 may further comprise at least oneliner fastening mechanism 158 disposed on a bottom surface 161 thereof,as shown in FIGS. 14, 15 and 17, for at least partially coupling a linermember 160 thereto. For example, as shown in the exemplary illustratedembodiment a pair of side liner fastening mechanisms 158 may be providedon a bottom surface 161 of the washable article 150. The least one linerfastening mechanism 158 and the opening 154 may be provided on the sameside of the washable article 150, such as the bottom side or surface161. The at least one liner fastening mechanism 158 may be any knownfastening mechanism capable of coupling the liner member 160. Forexample, the at least one liner fastening mechanism 158 may be one partof a multiple-part fastening mechanism that is configured to mate withanother part of the multiple-part fastening mechanism. In otherembodiments, the at least one liner fastening mechanism 158 may besingular and capable of coupling the washable article 150 to a linermember 160. For example, the at least one liner fastening mechanism 158may be the hook part of hook and loop fastener, such as the Velcro®brand hook and loop fastener system. In such an embodiment, the linermember 160 may be configured to be coupled to the washable article 150via the at least one “hook” liner fastening mechanism 158, such as beinga fabric or fabric-like material.

The at least one washable article 150 may also include one moreadditional fastening mechanism in addition to the at least one linerfastening mechanism 158. For example, the at least one washable article150 may also include at least one opening fastening mechanism 158Badjacent each least one liner fastening mechanism 158 and the opening155, as shown in FIGS. 15-16. The at least one opening fasteningmechanism 158B may be any known fastening mechanism. The at least oneopening fastening mechanism 158B may be one part of a multiple-partfastening mechanism, such as one part of a multiple-part fasteningmechanism that is configured to mate with another part of themultiple-part fastening mechanism. For example, in the illustratedexemplary embodiment the at least one opening fastening mechanism 158Bmay be configured to mate with the at least one liner fasteningmechanism 158. As the at least one liner fastening mechanism 158 of theexemplary illustrated washable article 150 may be one part of a hook andloop fastener adjacent opposing longitudinal sides of the washablearticle 150, the at least one opening fastening mechanism 158B may bethe other part of the hook and loop fastener such that the adjacentopening fastening mechanisms 158B and liner fastening mechanisms 158 arecapable of removably mating or coupling. In this manner, for example,the washable article 150 may be deformed such that adjacent openingfastening mechanisms 158B and liner fastening mechanisms 158 areremovably coupled or attached and, thereby, the opening 155 is “pulled”to an “open” position as partially shown in FIG. 14 (as compared to the“closed” state shown in FIG. 16).

As is known in the art, such a configuration may be advantageous if theliner fastening mechanisms 158 are configured such that they tend toattach or couple with other portions of the washable diaper 110 or otherclothes, fabrics, fastening mechanisms, etc. For example, if the linerfastening mechanisms 158 are the hook portion of a hook and loopfastener, the liner fastening mechanisms 158 may tend to attach orcouple to other portions of the washable diaper 110 or other fabricswhen the washable diaper 110 is not worn, such as when the outer article120 is being washed. In such a configuration, however, the liner andopening fastening mechanisms 158, 158B may be removably mated or coupledsuch that the liner fastening mechanisms 158 (and opening fasteningmechanisms 158B) are blocked-off or otherwise rendered incapable ofcoupling to other portions of the washable diaper 110 or other fabrics,clothes fastening mechanisms, etc. Further, as explained above when theliner and opening fastening mechanisms 158, 158B are coupled or attachedthe opening 155 is “opened” to an extent. Such an “open” configurationmay be advantageous because it may allow the at least one absorbent pad170 to become easily disengaged from the cavity 154 through the opening155 when the inner liner system 140 is not assembled with the outerarticle 120 or the washable diaper 110 is worn. For example, the “open”configuration of the opening 155 via the liner and opening fasteningmechanisms 158, 158B may allow the at least one absorbent pad 170 to befreed from the washable article 150 when the washable article 150 isremoved or disengaged from the outer article 120 and the othercomponents of the inner liner system 140 and washed during a typicalwash cycle of a typical washing machine. In this way, the at least oneabsorbent pad 170 may advantageously not need to be handled or otherwisemanually removed from the washable article 150, such as when the atleast one absorbent pad 170 and washable article 150 are soiled.

As shown in FIGS. 14-15C and 17, the at least one washable article 150may include at least one first end stiffening member or portion 156positioned proximate to the first end thereof and/or at least one secondend stiffening member 157 being positioned proximate to second end 152thereof. In some embodiments, the least one first and second endstiffening members 156, 157 may include at least one stiffening member(not shown). The at least one stiffening member may be fabricated from amore rigid material than used for the fabrication of the at least onewashable article 150. Exemplary stiffing member materials may includefabric, plastic, metal, polymers, elastomers and the like. In theillustrated exemplary embodiment, the first and second end stiffeningmembers 156, 157 are stiffer portions of the washable article 150 ascompared to other portions of the washable article, and are formed bythe material of the washable article 150 being stitched and/or foldedover upon itself at least once. Although the first and second endstiffening members 156, 157 are illustrated at or near the first andsecond ends 151, 152, they may alternatively be positioned in anylocation and orientation and be formed in any manner.

The at least one washable article 150 may also include at least onecompartment fastening mechanism 153, as shown in FIGS. 14-15C and 17.The at least one compartment fastening mechanism 153 may be configuredto couple at least the at least one washable article 150 to the outerarticle 120, as described above. The at least one compartment fasteningmechanism 153 may be coupled to the washable article 150 by any means,and may take the form of any known fastening mechanism in the art. As anon-limiting example, the at least one compartment fastening mechanism153 may be at least one half or mate of a hook and loop fastener, suchas a Velcro® brand hook and loop fastener system, a hook and eyefastener, pin fastener, button fastener, snap button or claspmechanisms, or the like. As the at least one fastening mechanism 131 ofthe exemplary illustrated outer article 120 are one half or mate of apress, spring or snap button, the at least one compartment fasteningmechanism 153 may be the other half or mate of the press, spring or snapbutton such that the at least one fastening mechanism 131 of the outerarticle 120 and the at least one compartment fastening mechanism 153 arecapable of removably mating or coupling. Further, the number andpositioning of the at least one compartment fastening mechanism 153 ofthe washable article 150 may vary. For example, the at least onecompartment fastening mechanism 131 may be positioned proximate the sideand longitudinal edges of the washable article (e.g., a compartmentfastening mechanism 131 proximate each corner of the washable article150) to substantially align with the fastening mechanisms 131 of thefirst and second compartments 123, 124 of the outer article 120. In suchan arrangement, the compartment fastening mechanisms 153 allow thewashable article 150 to be removably coupled to the outer article 120such that the first and second ends 151, 152 of the washable article 150are removably coupled and secured within the first and secondcompartments 123, 124 of the outer article 120, respectively, as shownin FIG. 17. Further, because the at least one absorbent pad 170 may bepositioned within the cavity 154 of the washable article 150, the atleast one absorbent pad 170 may also be removably coupled to the outerarticle 120 via the compartment fastening mechanisms 131 and thefastening mechanism 153 of the outer article 120.

As shown in FIGS. 14-17, the at least one liner member 160 may also beconfigured with the at least one washable article 150 such that theliner member 160 is secured to the outer article 120 via the compartmentfastening mechanisms 153 of the washable article 150 and the fasteningmechanism 131 of the outer article 120, as well as the at least oneliner fastening mechanism 158 of the washable article 150. As shown bestin FIGS. 15A-C, the at least one liner member 160 may define a first end171 and a second end 172 and a longitudinal length therebetween. Thelongitudinal length of the liner member 160 may be substantially similarto the longitudinal length of the washable article 150 extending betweenthe first and second ends 151, 152 thereof. The width of the linermember 160 may be substantially greater to the width of the washablearticle 150. In other embodiments however, the length of the linermember 160 may be greater to or less than that of the washable article150, and/or the width of the liner member 160 may be equal to or lessthan that of the washable article 150.

With reference to FIGS. 15A-C, when one embodiment of the washablediaper 110 is assembled, the at least one absorbent pad 170 is insertedthrough the opening 155 and into the cavity 154 of the washable article150. As shown in FIG. 15A, once the absorbent pad 170 is positionedwithin the washable article 150, the top surface (not shown) of thewashable article 150 may be positioned on the at least one liner member160 such that the first and second ends 151, 152 of the washable article150 substantially align with the first and second ends 171, 172 of theliner member 160 and the washable article 150 is positioned in a medialportion of the width of the liner member 160. Due to the width of theliner member 160 as compared to the width of the washable article 150and the positioning of the compartment fastening mechanisms 153, theportions of the width of the liner member 160 that expand past the sideedges of the washable article 150 may be folded over the washablearticle 150 such that the liner member 160 at least lies over andsubstantially covers the compartment fastening mechanisms 153 as shownin FIGS. 15B and 15C. As shown in FIGS. 15B-16, once the liner member160 is wrapped or folded over the width of the washable article 150, theliner fastening mechanisms 158 of the washable article 150 may engagethe liner member 160 at a medial portion of the length of the linermember 160, for example, to at least initially removably secure orattach the liner member 160 to the washable article 150 (and thereby theabsorbent pad 170).

Once the liner member 160 is wrapped about the washable article 150 (andtherefore the top surface (not shown) of the washable article 150substantially covers by the liner member 160) and the liner fasteningmechanisms 158 of the washable article 150 engage the liner member 120,the inner liner system 140 may be considered formed, constructed orassembled, as shown in FIG. 17. As also shown in FIGS. 10 and 17, theinner liner system 140 may be coupled to the outer article 120 to formthe washable diaper 110 when formed, constructed or assembled. Asillustrated in FIG. 17, the compartment fastening mechanisms 153 of thewashable article 120 and the fastening mechanisms 131 of the outerarticle 120 may be coupled with the liner member 160 held therebetween.In this manner, the inner liner system 140 can be detachably secured orcoupled to the outer article 120 such that the first end 141 of theinner liner system 140 and an adjacent portion thereof is positioned andselectively secured within the first or front compartment 123, and suchthat the second end 142 of the inner liner system 140 and an adjacentportion thereof is positioned and selectively secured within the secondor back compartment 124, as shown in FIG. 10. More specifically and alsoillustrated in FIG. 10, the inner liner system 140 can be detachablesecured or coupled to the outer article 120 such that the first or frontends 151, 171 of the washable article 150 and the liner member 160 andadjacent portions thereof are positioned and selectively secured withinthe first or front compartment 123, and such that the second ends 152,172 of the washable article 150 and the liner member 160 and adjacentportions thereof are positioned and selectively secured within thesecond or back compartment 124. Further, the inner liner system 140 maybe held within the medial portion of the width of the outer article 120by the side barriers 127, 128.

So that the washable article 150 is capable of securing to the outerarticle 120 via the compartment fastening mechanisms 153 of the washablearticle 120 and the fastening mechanisms 131 of the outer article 120,in some embodiments the liner member 160 may have a thickness,flexibility and other properties that allows for liner member 160 to besecured between compartment fastening mechanisms 153 and the fasteningmechanisms 131 without effectively altering their fasteningcapabilities. Alternatively, liner member 160 may include apertures (notshown) aligned with the compartment fastening mechanisms 153 and thefastening mechanisms 131 so that they can be coupled together throughthe liner member 160.

In the illustrated exemplary embodiment, the liner member 160 isgenerally compliant, soft feeling, and non-irritant to the wearer'sskin. In some embodiments, the liner member 160 may be fabricated from aliquid pervious material, including but not limited to, rice paper,cellulose fibers, blend of rayon and cellulose fibers and any othernatural or synthetic liquid permeable hydrophobic fibrous materials thatwill allow liquid to readily penetrate through its thickness. The linermember 160 may also be fabricated from a material that will wickmoisture away from the wearer's skin. The liner member 160 may furtherbe fabricated from any material that is biodegradable and flushablethrough a regular toilet system. When the liner member 160 is fabricatedfrom a liquid pervious, flushable material, it may function to containnon-liquid bodily excrements and allow for easy disposal via a regularseptic/sewer system, as well as allow liquid excrement to pass throughthe liner member 160 and into the washable article 150 and absorbent pad170.

As shown in FIG. 19, the outer article 120 may include any design oraesthetic pleasing ornamentation on the outer surface or layer 130. Forexample, the outer surface or layer 130 may include a design, such as apattern or depiction that an adult or child would find aestheticallypleasing. As another example, as shown in FIG. 19 the outer surface orlayer 130 may include ornamentation 190 detachably or permanentlycoupled thereto that resembles a pocket or other typical “adult”clothing characteristics, such as one or more pocket positioned on theouter surface or layer 130 of the outer article. In some embodiments,the pocket ornamentation 190 may be detachable, and only one pocketornamentation 190 may be provided on the back side of the outer surfaceor layer 130 of the outer article 120. Further, in some embodiments theornamentation 190 on the outer surface or layer 130 of the outer article120 may serve a utilitarian purpose, such as for storage,identification, style or the like.

Turning to FIGS. 20-22, an exemplary partial method of manufacturing anouter article is shown, and the outer article is generally indicated bythe reference numeral 320. Exemplary outer article 320 is similar to theembodiments of exemplary outer articles 20, 120 and 220 described abovein connection with FIGS. 1-19, and therefore like reference numeralspreceded by the number “3”, as opposed to the number “1” or “2”, areused to indicate like elements. Like exemplary illustrated outerarticles 20, 120 and 220, exemplary illustrated outer article 320 may beassembled with an inner liner system (no shown) to form a washablediaper (not shown). The description above with reference to exemplaryouter articles 20, 120 and 220 may therefore apply to particularcomponents, systems, features or the like of exemplary outer article 320and is not repeated hereinafter for brevity.

As shown in FIG. 20, a method of manufacturing an outer article 320 maycomprise the step of removing, forming or otherwise manufacturing agenerally hourglass-shaped stock 392 of liquid pervious material ormaterials. When formed of liquid impervious material, the generallyhourglass-shaped stock 392 may be the inner layer 329 of the outerarticle 320. In some other embodiments, the generally hourglass-shapedstock 392 may be the outer layer 330 of the outer article 320. Forexample, if the generally hourglass-shaped stock 392 is not formed fromliquid impervious material, the generally hourglass-shaped stock 392 maybe an outer layer 330. The generally hourglass-shaped stock 392 may bedirectly removed from a single piece of liquid pervious material, or maybe removed in stages or steps. Further, in some embodiments multiplehourglass-shaped stocks 392 are removed from liquid pervious material atthe same time, such as stamping a stack of liquid pervious material witha cutter that is shaped substantially similar to the hourglass-shapedstock 392. In some embodiments a template shaped substantially similarto the hourglass-shaped stock 392 may be used to obtain, produce orotherwise manufacture the hourglass shaped stock 392 of liquid perviousmaterial or materials.

The hourglass-shaped stock 392 may include the first and second portions385, 386 of the first and second compartments 323, 324 as adjacentintegral components. In the illustrated exemplary embodiment of thehourglass-shaped stock 392 the first and second opposing extendedportions 336, 337 of the first and second portions 385, 386 may includefirst and second interior extending portions 336B, 337B, respectively,to delineate the first and second portions 385, 386, as best shown inFIG. 20. As explained further below, the first and second interiorextending portions 336B, 337B may facilitate the forming or manufactureof the first and second liquid pervious compartments 332, 334. Inalternative embodiments, the first and second portions 385, 386 of thefirst and second compartments 323, 324 may be formed separately, such asforming the hourglass-shaped stock 392 with the first portions 385 andforming the second portions 386 separately (i.e., the second portions386 may be discrete). Similarly, as shown in FIG. 20 the opposing sidebarriers 327, 328 may be formed separately from the hourglass-shapedstock 392 as side barriers stock 392B. However, in alternativeembodiments the hourglass-shaped stock 392 may include the opposing sidebarriers 327, 328 integral therewith, as indicated by the dashed line326 as compared to if the opposing side barriers 327, 328 are formedfrom separate and distinct side barrier stock 392B, as shown in FIG. 20.

Once an hourglass-shaped stock 392 of liquid impervious material isformed, the hourglass-shaped stock 392 can be further formed into anouter article 320 through additional processing steps. For example, asshown in FIG. 21 the opposing side barriers 327, 328 may be coupled tothe opposing sides 325, 326 of the hourglass-shaped stock 392. In someembodiments, the opposing sides 325, 326 of the hourglass-shaped stock392 may be coupled to the opposing sides 325, 326 of thehourglass-shaped stock 392 by stitching (i.e., sewn thereto). As alsoshown in FIG. 21, the second portions 386 may be folded over the firstportions 385 toward the medial portion 339 of the hourglass-shaped stock392 at the first and second interior extending portions 336B, 337B. Assuch, the first and second interior extending portions 336B, 337B may beused as a guide as to where the second portions 386 should be foldedover the first portions 385. Thereby, the “fold-line” formed by placingthe first and second portions 385, 386 in aligned abutment forms thefirst and second ends 321, 322 of the outer article 320 and a liquidimpervious bottom edge to the first and second compartments 323, 324,respectively.

With the first and second portions 385, 386 in aligned abutment with thesecond portion 386 overlying the first portion 385, the side edges ofthe first and second compartments 323, 324 may be sealed such that theyare liquid impervious. For example, as shown in FIG. 22, liquidimpervious material or portions 380 may be affixed over the side edgesof the first and second compartments 323, 324 such that the side edgesare substantially liquid impervious. In this way, the side edges andfirst and second ends 321, 322 of the first and second compartments 323,324, respectively, are liquid impervious and the portion facing themedial portion 339 of the outer article is “open”. In such anembodiment, fastening support members 382 with liner system fasteningmembers 331 may be coupled within the first and second compartments 323,324. For example, liquid impervious material or portions 380 may beaffixed over the front and back sides 321, 322 such that the front andback sides 321, 322 are liquid impervious, and the fastener supportmembers 382 may be coupled to the outer article 320 via the affixing ofthe material or portions 380. In some embodiments, the liquid imperviousmaterial or portions 380 may be banding stitched over the front and backsides 321, 322 with non-wicking thread, and the fastening supportmembers 382 may be positioned adjacent the front and back sides 321, 322between the first and second portions 385, 386 such that the threadaffixes the banding, first and second portions 385, 386 and fasteningsupport members 382 together. In some embodiments, the thread ispolyester thread sewn via a ball needle.

As also shown in FIG. 22, the liquid impervious material or portion 380may be applied over the edges and substantially about the perimeter ofthe outer article 320, including the side edges 325, 326 where theopposing side barrier 327, 328 are coupled to the outer article 320. Incontrast, however, the outer edges of the opposing side barrier 327, 328may not include the liquid impervious material or portion 380. Instead,the outer edges of the opposing side barrier 327, 328 may include anelastic member 388 coupled thereto. For example, the elastic member 388may be couple to the outer edges of the opposing side barrier 327, 328in an elongated or stretched orientation or state, such that in aneutral position the elastic member 388 may act to shorten thelongitudinal length of the opposing side barrier 327, 328. In this way,the opposing side barrier 327, 328 may act to cup or bowl the outerarticle 320 into a shape that is conducive to being worn as a washablediaper 310. Further, the manner which the opposing side barrier 327, 328are attached to the side edges 325, 326 of the washable article 320,such as by banding being sewn over the edges thereof, may tend toencourage or promote the opposing side barrier 327, 328 from extendingaway from the inner surface or layer 339. In such a configuration, theopposing side barrier 327, 328 may be effective in preventing leakagefrom the interior of the washable article 320 and enhance the comfortand fit of the washable article 320 to a user.

The outer article 320 may include further processing, such theapplication of fastening mechanism configured to allow the outer article320 to be wrapped around a users waist and legs and removable coupledthereto. Further, covers or shields for the fastening mechanisms mayalso be provided to prevent the fastening mechanism from inadvertently“coupling”, such as when the outer article 320 is washed. Still further,the washable article may include several layers, and such layers may becoupled together via one or more independent step, or during one of thepreviously discussed steps. For example, the application of the liquidimpervious members or portions 380 may be effective in coupling severallayers of the outer article 320 to one another.

As may be recognized by those of ordinary skill in the pertinent artbased on the teachings herein, numerous changes and modifications may bemade to the above-described and other embodiments of the presentinvention without departing from the spirit of the invention as definedin the claims. For example, the components of the washable diaper may bemade of any of numerous different materials that are currently or laterbecome known for performing the functions of such components. Inaddition, not all elements or all features disclosed herein arenecessary, and if desired, additional elements or features may be added.Further, components, aspects or combinations thereof described with aparticular embodiment may be incorporated in another describedembodiment to achieve the same or similar function as it achieved in theparticular embodiment. Similarly, the components of the washable diapermay take any of numerous different shapes and/or configurations.

Accordingly, this detailed description of the illustrated and exemplaryembodiments of the present invention is to be taken in an illustrative,as opposed to a limiting sense.

What is claimed is:
 1. A washable diaper comprising: an outer articleconfigured with a first end including a first substantially liquidimpervious compartment formed between overlapping first and secondlayers of substantially liquid impervious material, a second endincluding a second substantially liquid impervious compartment formedbetween overlapping third and fourth layers of substantially liquidimpervious material, and a medial portion with opposing side edgesextending between the first and second ends thereof, and furthercomprising an inner surface and an outer surface; and an inner linersystem comprising at least one washable article having a first end and asecond end, wherein when the inner liner system is assembled with theouter article the inner liner system is detachably coupled to the outerarticle adjacent the inner surface thereof, the first end of at leastthe at least one washable article of the inner liner system ispositioned within the first compartment between the overlapping firstand second layers of substantially liquid impervious material of theouter article, and at least the second end of the at least one washablearticle of the inner liner system is positioned within the secondcompartment between the overlapping third and fourth layers ofsubstantially liquid impervious material of the outer article, wherein,when the inner liner system is assembled with the outer article and thewashable diaper is worn by a user, the first and third layers ofsubstantially liquid impervious material are each positioned between theuser and the washable article, wherein the first and second ends of thewashable article define opposing ends of the inner liner system, whereinthe first and second layers of substantially liquid impervious materialof the first compartment, the third and fourth layers of substantiallyliquid impervious material of the second compartment, and the medialportion define an outer perimeter of the outer article, and wherein atleast the portions of the outer perimeter of the outer member defined byfirst and second compartments include at least one substantially liquidimpervious member sewn thereover with substantially non-wicking thread.2. The washable diaper of claim 1, wherein the entirety of the outerperimeter of the outer article includes at least one substantiallyliquid impervious member sewn thereover with substantially non-wickingthread.
 3. The washable diaper of claim 1, wherein a first portion ofthe at least one substantially liquid impervious member is adjacent andsewn to the first layer of substantially liquid impervious material, asecond portion of the at least one substantially liquid imperviousmember is adjacent and sewn to the second layer of substantially liquidimpervious material, and a third portion of the at least onesubstantially liquid impervious member extending between the first andsecond portions thereof extends over the first compartment formedbetween the first and second layers of substantially liquid imperviousmaterial.
 4. The washable diaper of claim 1, wherein the substantiallynon-wicking thread is a polyester thread.
 5. The washable diaper ofclaim 1, wherein each of the first and second compartments include anopening accessible from the medial portion of the inner surface of theouter article, and wherein when the inner liner system is assembled withthe outer article the at least one washable article extends through eachopening.
 6. The washable diaper of claim 1, wherein the outer articleincludes a substantially liquid impervious material, and wherein thefirst and second layers of substantially liquid impervious material areformed from the substantially liquid impervious material of the outerarticle being folded over upon itself such that the inner surface of thesubstantially liquid impervious material of the outer article formsopposing interior surfaces of the first substantially liquid imperviouscompartment.
 7. The washable diaper of claim 6, wherein said at leastone substantially liquid impervious member and substantially non-wickingthread forms substantially liquid impervious opposing sides edges of thefirst and second substantially liquid impervious compartments.
 8. Thewashable diaper of claim 1, wherein the washable diaper furthercomprises at least one fastening mechanism for detachably coupling theinner liner system to the outer article such that the first end of theinner liner system is selectively secured within the first substantiallyliquid impervious compartment of the outer article and the second end ofthe inner liner system is selectively secured within the secondsubstantially liquid impervious compartment of the outer article.
 9. Thewashable diaper of claim 8, wherein the at least one fastening mechanismincludes a first fastening mechanism comprising a first componentassociated with the outer article and a second component for mating withthe first component associated with the at least one washable articlefor detachably coupling the inner liner system to the outer article suchthat the first end of at least the at least one washable article isselectively secured within the first substantially liquid imperviouscompartment of the outer article, and wherein the at least one fasteningmechanism further includes a second fastening mechanism comprising athird component associated with the outer article and a fourth componentfor mating with the third component associated with the at least onewashable article for detachably coupling the inner liner system to theouter article such that the second end of at least the at least onewashable article is selectively secured within the second substantiallyliquid impervious compartment of the outer article.
 10. The washablediaper of claim 9, wherein the inner liner system further comprises aliner member fabricated from a substantially liquid perviousbiodegradable material, and wherein the at least one fastening mechanismdetachably couples the liner member to the outer article and the atleast one washable article such that at least a portion of the linermember substantially covers at least a portion of an inner surface ofthe at least one washable article when the inner liner system isassembled with the outer article.
 11. The washable diaper of claim 1,wherein the at least one washable article includes an internal cavitywith an opening, and wherein the inner liner system further comprises atleast one absorbent pad removably secured within the internal cavity.12. The washable diaper of claim 11, wherein the at least one washablearticle includes fastening mechanisms configured to bias the opening inan open position when the fastening mechanisms are fastened to eachother, and wherein the longitudinal length of the opening is at leastabout 80% of the longitudinal length of the at least one absorbent pad.13. The washable diaper of claim 1, wherein a portion of the medialportion of the outer perimeter of the outer article comprises sidebarrier assemblies at the opposing side edges, wherein each side barrierassembly comprises a substantially liquid impervious barrier panel witha generally semicircle shape including a substantially curved edge and asubstantially linear edge.
 14. The washable diaper of claim 13, whereineach side barrier assembly comprises substantially liquid imperviousbanding secured over the substantially curved edge of the correspondingbarrier panel and the corresponding side edge of the outer perimeter ofthe outer article with substantially non-wicking thread such that thebarrier panel and the outer article are coupled to one another, form asubstantially liquid impervious seal therebetween, and the correspondingbarrier panel is biased in a direction extending substantially away fromthe inner surface of the outer article.
 15. The washable diaper of claim13, wherein a portion of the medial portion of the outer articlecomprises side barrier assemblies at the opposing side edges, andwherein each side barrier assembly comprises an elasticized membercoupled to the substantially linear edge of the corresponding barrierpanel such that the elasticized member biases at least the inner surfaceof the medial portion of the outer article into a generally convexshape.
 16. The washable diaper of claim 1, wherein the outer articleincludes a generally pocket-shaped member removably attached to theouter surface thereof proximate to the second end.
 17. A method ofassembling a washable diaper, the method comprising: obtaining areusable outer article having a front end edge, a back end edge, amedial portion with opposing side edges extending between the front andback end edges thereof, an outer surface and an inner surface, whereinthe inner surface includes a first substantially liquid imperviouscompartment formed between overlapping first and second layers ofsubstantially liquid impervious material defining the front end edge andportions of the opposing side edges of the reusable outer article and asecond substantially liquid impervious compartment formed betweenoverlapping third and fourth layers of substantially liquid imperviouslayers defining the back end edge and portions of the opposing sideedges of the reusable outer article, the front end edge, back end edge,and opposing side edges define an outer perimeter of the outer article;obtaining at least one washable article having a first and a second endand inner and outer surfaces; and detachably coupling the at least onewashable article to the reusable outer article and positioning the firstend of the at least one washable article within the first substantiallyliquid impervious compartment between the overlapping first and secondlayers of substantially liquid impervious material of the reusable outerarticle and the second end of the at least one washable article withinthe second substantially liquid impervious compartment between theoverlapping third and fourth layers of substantially liquid imperviousmaterial of the reusable outer article, and wherein when the inner linersystem is assembled with the outer article and the washable diaper isworn by a user, the first and third layers of substantially liquidimpervious material are each positioned between the user and thewashable article, wherein the first and second ends of the washablearticle define opposing ends of the inner liner system, and wherein atleast the portions of the outer perimeter of the outer article definedby the first and second substantially liquid impervious compartmentsinclude at least one substantially liquid impervious member sewnthereover with substantially non-wicking thread.
 18. The method of claim17, wherein the first and second substantially liquid imperviouscompartments include an opening accessible from the medial portion ofthe reusable outer article, wherein the outer article comprises asubstantially liquid impervious material, and wherein each of the firstand second compartments of the outer article are formed at least in partfrom the substantially liquid impervious material of the outer article.19. The method of claim 18, wherein each of the first, second, third andfourth layers of substantially liquid impervious material of the outerarticle are formed at least in part by the substantially liquidimpervious material of the outer article being folded over upon itself.20. The method of claim 19, wherein the entirety of the outer perimeterof the outer article includes at least one substantially liquidimpervious member sewn thereover with substantially non-wicking thread.21. The method of claim 17, wherein the outer article and the at leastone washable article include mating fastening mechanisms for detachablycoupling the at least one washable article to the reusable outer articlesuch that at least the first end of the at least one washable article isselectively secured within the first substantially liquid imperviouscompartment of the reusable outer article and at least the second end ofthe at least one washable article is selectively secured within thesecond substantially liquid impervious compartment of the reusable outerarticle when the fastening mechanisms are coupled to one another, andwherein the step of detachably coupling the at least one washablearticle to the reusable outer article includes fastening the matingfastening mechanisms to one another.
 22. The method of claim 19, furthercomprising the steps of: obtaining a liner member fabricated from asubstantially liquid pervious biodegradable material; substantiallycovering at least a portion of the inner surface of the at least onewashable article with the liner member; and detachably coupling theliner member to the at least one washable article and the reusable outerarticle.
 23. The method of claim 22, wherein the steps of detachablycoupling the liner member to the at least one washable article and thereusable outer article, and detachably coupling the at least onewashable article to the reusable outer article are accomplished at leastin part by coupling mating fastening mechanisms associated with the atleast one washable article and the reusable outer article to oneanother.
 24. The method of claim 17, further including the steps of:obtaining at least one absorbent pad; removably positioning the at leastone absorbent pad within a cavity in the at least one washable articlethrough an opening in the at least one washable article; and unfasteningfastening members provided on the one washable article that are coupledto each other and thereby biasing the opening of the washable article inan open position to bias the opening in a closed position.
 25. A methodof manufacturing a washable diaper, the method comprising: manufacturingan outer article of the washable diaper comprising: forming a firstsubstantially liquid impervious portion of a shape that includes a frontend, a back end, a medial portion with opposing side edges extendingbetween the front and back ends, an outer surface and an inner surface;folding a first compartment portion of the first substantially liquidimpervious portion that is adjacent to the front end over the innersurface and towards the back end thereof such that the inner surfaces ofthe first compartment portion and the adjacent portion of the firstsubstantially liquid impervious portion overlap to form a firstsubstantially liquid impervious compartment therebetween with asubstantially liquid impervious edge at the fold which forms a front endedge of the outer article, and an opening accessible from the innersurface of the medial portion of the first substantially liquidimpervious portion; coupling substantially liquid impervious bandingover at least the side edges and the front end edge of the firstsubstantially liquid impervious compartment with substantiallynon-wicking thread such that the side edges and the front end edge ofthe first substantially liquid impervious compartment are substantiallyliquid impervious; folding a second compartment portion of the firstsubstantially liquid impervious portion that is adjacent to the back endover the inner surface and towards the front end thereof such that theinner surfaces of the first compartment portion and the adjacent portionof the first substantially liquid impervious portion overlap to form asecond substantially liquid impervious compartment therebetween with asubstantially liquid impervious edge at the fold forming a back end edgeof the outer article and an opening accessible from the inner surface ofthe medial portion of the first substantially liquid impervious portion;and coupling substantially liquid impervious banding over at least theside edges and the back end edge of the second substantially liquidimpervious compartment with substantially non-wicking thread such thatthe side edges and the back end edge of the second substantially liquidimpervious compartment are substantially liquid impervious.
 26. Themethod of claim 25, wherein forming the first substantially liquidimpervious portion includes cutting the first substantially liquidimpervious portion out from substantially liquid impervious material.27. The method of claim 25, wherein the coupling substantially liquidbanding over at least the side edges and the front end edge of the firstcompartment and over at least the side edges and the back end edge ofthe second compartment comprises sewing the substantially liquid bandingwith polyester thread via a ball needle.
 28. The method of claim 25,wherein the sewing of the substantially liquid impervious bandingportions over at least the side edges and the front end edge of thefirst compartment includes passing the substantially non-wicking threadat least through the substantially liquid impervious banding portions afirst time, the first compartment portion of the first substantiallyliquid impervious portion, the portion of the first substantially liquidimpervious portion adjacent the first compartment portion forming thefirst compartment, and the substantially liquid impervious portions asecond time, and wherein the sewing of the substantially liquidimpervious banding portions over at least the side edges and the backend edge of the second compartment includes passing the substantiallynon-wicking thread at least through the substantially liquid imperviousbanding portions a first time, the second compartment portion of thefirst substantially liquid impervious portion, the portion of the firstsubstantially liquid impervious portion adjacent the second compartmentportion forming the second compartment, and the substantially liquidimpervious substantially impervious material a second time.
 29. Themethod of claim 25, wherein manufacturing an outer article of thewashable diaper further comprises manufacturing side barrier assemblieson the medial portion of the first substantially liquid imperviousportion at each opposing side edge thereof, comprising: forming secondand third substantially liquid impervious portions of a generallysemicircle shape including a substantially curved edge and asubstantially linear edge; securing substantially liquid imperviousbanding over the substantially curved edge of the second substantiallyliquid impervious portion and one of the opposing side edges of thefirst substantially liquid impervious portion with substantiallynon-wicking thread such that the first and second portions are coupledto one another, form a substantially liquid impervious sealtherebetween, and the second portion is biased in a direction extendingsubstantially away from the inner surface of the first portion; securingsubstantially liquid impervious banding over the substantially curvededge of the third substantially liquid impervious portion and the otherof the opposing side edges of the first substantially liquid imperviousportion with substantially non-wicking thread such that the first andthird portions are coupled to one another, form a substantially liquidimpervious seal therebetween, and the third portion is biased in adirection extending substantially away from the inner surface of thefirst portion; and securing an elasticized member to the substantiallylinear edge of each of the second and third substantially liquidimpervious portions such that the elasticized members bias at least theinner surface of the first substantially liquid impervious portion intoa generally convex shape.
 30. An inner liner system for use with asubstantially liquid impervious outer article of a washable diaper,comprising: an elongate washable article defining a first longitudinallength greater than a first lateral width and including an internalcavity and a longitudinally extending opening in a medial portion of thefirst width in communication with the internal cavity that defines asecond longitudinal length, wherein the washable article issubstantially liquid pervious and absorbent, an absorbent pad that issubstantially liquid pervious and absorbent that defines a thirdlongitudinal length, and coupling mechanisms for coupling to thesubstantially liquid impervious outer article of the washable diaper,wherein the absorbent pad and the internal cavity of the washablearticle are configured such that the absorbent pad can be carried withinthe cavity when the inner liner system is used with the substantiallyliquid impervious outer article, and wherein the cavity is a hollowspace within the interior of the washable article that is substantiallysurrounded by the washable article except for the opening thereof. 31.The inner liner system of claim 30, wherein the second longitudinallength of the opening of the washable article is at least about 80% ofthe third longitudinal length of the absorbent pad.
 32. The inner linersystem of claim 31, wherein the at least one washable article includesfastening mechanisms configured to bias the opening in an open positionwhen the fastening mechanism are fastened to each other.
 33. The methodof claim 25, including assembling an inner liner system comprising atleast one washable article having a first end and a second end with theinner surface of the outer article such that the first end of thewashable article is fully positioned within the first compartment of theouter article and the second end of the washable article is fullypositioned within the second compartment of the outer article.
 34. Thewashable diaper of claim 1, wherein the at least one substantiallyliquid impervious member forms the perimeter of each of the first andsecond substantially liquid impervious compartments.
 35. The washablediaper of claim 1, further comprising substantially liquid imperviousbarrier panels coupled to portions of the opposing side edges of theperimeter of the medial portion of the outer article, and wherein the atleast one substantially liquid impervious member is sewn over thejunctions of the substantially liquid impervious barrier panels and theopposing side edges of the perimeter of the medial portion of the outerarticle with substantially non-wicking thread.